087178

ARMY *TM 9-2320-272-23-4 AIR FORCE *TO 36A12-1C-1155-2-4
TECHNICAL MANUAL FIELD MAINTENANCE MANUAL FOR

TRUCK, 5-TON, 6X6, M939, M939A1, AND M939A2 SERIES TRUCKS (DIESEL)
TRUCK, CARGO: 5-TON, 6X6 DROPSIDE
NSN NSN NSN NSN NSN NSN M923 2320-01-050-2084 M923A1 2320-01-206-4087 M923A2 2320-01-230-0307 M925 2320-01-047-8769 M925A1 2320-01-206-4088 M925A2 2320-01-230-0308 (EIC BRY) (EIC BSS) (EIC BS7) (EIC BRT) (EIC BST) (EIC BS8)
TRUCK, DUMP: 5-TON, 6X6

NSN NSN NSN NSN NSN NSN M929 2320-01-047-8756 M929A1 2320-01-206-4079 M929A2 2320-01-230-0305 M930 2320-01-047-8755 M930A1 2320-01-206-4080 M930A2 2320-01-230-0306 (EIC BTH) (EIC BSY) (EIC BTN) (EIC BTG) (EIC BSZ) (EIC BT7)
TRUCK, VAN, EXPANSIBLE: 5-TON, 6X6

M934 NSN 2320-01-047-8750 (EIC BTB) M934A1 NSN 2320-01-205-2682 (EIC BS4) M934A2 NSN 2320-01-230-0300 (EIC BTR)
TRUCK, MEDIUM WRECKER: 5-TON, 6X6

M936 NSN 2320-01-047-8754 (EIC BTF) M936A1 NSN 2320-01-206-4078 (EIC BS6) M936A2 NSN 2320-01-230-0304 (EIC BTT)
TRUCK, CARGO: 5-TON, 6X6 XLWB

M927 NSN 2320-01-047-8771 (EIC BRV) M927A1 NSN 2320-01-206-4089 (EIC BSW) M927A2 NSN 2320-01-230-0309 (EIC BS9) M928 NSN 2320-01-047-8770 (EIC BRU) M928A1 NSN 2320-01-206-4090 (EIC BSX) M928A2 NSN 2320-01-230-0310 (EIC BTM)
TRUCK, TRACTOR: 5-TON, 6X6

M931 NSN 2320-01-047-8753 M931A1 NSN 2320-01-206-4077 M931A2 NSN 2320-01-230-0302 M932 NSN 2320-01-047-8752 M932A1 NSN 2320-01-205-2684 M932A2 NSN 2320-01-230-0303 (EIC BTE) (EIC BS2) (EIC BTP) (EIC BTD) (EIC BSZ) (EIC BTQ)
*SUPERSEDURE NOTICE - This manual supersedes TM 9-2320-272-24-1, TM 9-2320-272-24-2, TM 9-2320-272-24-3, TM 9-2320-272-24-4 and TO 36A12-1C-1155-2-1, TO 36A12-1C-1155-2-2, TO 36A12-1C-1155-2-3, & TO 36A12-1C-11 55-2-4, dated 30 June 1998, including all changes
DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENTS OF THE ARMY AND THE AIR FORCE 10 SEPTEMBER 2012
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TM 9-2320-272-23-4
WARNING SUMMARY
This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of the vehicle. Failure to observe these precautions or operating this vehicle without training or instruction may result in serious injury or death to personnel. FIRST AID DATA For information on first aid, refer to FM 4-25.11, First Aid. EXPLANATION OF SAFETY WARNING ICONS
EAR PROTECTION - Headphones over ears show that noise level will harm ears.
ELECTRICAL - Electrical wire to hand with electricity symbol running through hand shows that shock hazard is present.
EYE PROTECTION - Person with goggles shows that the material will injure the eyes.
FIRE - Flame shows that a material may ignite and cause burns.
HEAVY OBJECT - Human figure stooping over heavy object shows physical injury potential from improper lifting technique.
HEAVY PARTS - Hand with heavy object on top shows that heavy parts can crush and harm.
HEAVY PARTS - Foot with heavy object on top shows that heavy parts can crush and harm.
HEAVY PARTS - Heavy object pinning human figure against wall shows that heavy, moving parts present a danger to life or limb.
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WARNING SUMMARY - Continued

EXPLANATION OF SAFETY WARNING ICONS - Continued
HEAVY PARTS - Heavy object on human figure shows that heavy parts present a danger to life or limb.
HOT AREA - Hand over object radiating heat shows that part is hot and can burn.
MOVING PARTS - Hand with fingers caught between gears shows that the moving parts of the equipment present a danger to life or limb.
RADIATION - Three circular wedges shows that the material emits radioactive energy and can injure human tissue.
SLICK FLOOR - Wavy line on floor with legs prone shows that slick floor presents a danger for falling.
VAPOR - Human figure in a cloud shows that material vapors present a danger to life or health.
TM 9-2320-272-23-4
GENERAL SAFETY WARNINGS DESCRIPTION
WARNING
Ensure electrical power is off prior to working on all electrical connections. Prior to working on or around vehicle, remove all jewelry, such as rings, ID tags, bracelets, etc. Jewelry, and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel.
WARNING
Personnel hearing can be permanently damaged if exposed to constant high noise levels of 85 dB or greater. Failure to comply may reslult in injury to personnel.
WARNING
Unless otherwise specified, perform all maintenance procedures with all attachments lowered to the ground, pilot shutoff lever in the up position, and engine shut off. Failure to comply may result in injury or death to personnel.
TM 9-2320-272-23-4
EXPLANATION OF HAZARDOUS MATERIALS ICONS
BIOLOGICAL - Abstract symbol bug shows that a material may contain bacteria or viruses that present a danger to life or health.
CHEMICAL - Drops of liquid on hand shows that the material will cause burns or irritation to human skin or tissue.
EXPLOSION - Rapidly expanding symbol shows that the material may explode if subjected to high temperatures, sources of ignition, or high pressure.
POISON - Skull and crossbones symbol shows that dangerous gases, sprays, vapors, liquids, or materials contain compounds that present a danger to life or health.
TM 9-2320-272-23-4

HAZARDOUS MATERIALS DESCRIPTIONS
WARNING
CARBON MONOXIDE Carbon monoxide is a colorless, odorless, deadly poison which, when breathed, deprives the body of oxygen and causes suffocation. Exposure to air containing carbon monoxide produces symptoms of headache, dizziness, loss of muscular control, apparent drowsiness, and coma. Permanent brain damage or death to personnel can result from severe exposure. Carbon monoxide occurs in exhaust fumes from internal combustion engines. It also occurs in exhaust fumes from engine coolant heater (arctic machine only). Carbon monoxide can become dangerously concentrated under conditions of inadequate ventilation. The following precautions must observed to ensure safety of personnel when engine of vehicle is operated. 1. 2. 3. 4. DO NOT operate engine in enclosed area without adequate ventilation. DO NOT idle engine without adequate ventilation. DO NOT drive machine with inspection plates or cover plates removed. BE ALERT for exhaust poisoning symptoms. They are: Headache Dizziness Sleepiness
Loss of muscular control 5. If you see another person with exhaust poisoning symptoms: Remove person from area Expose to fresh air Keep person warm DO NOT permit physical exercise Administer cardiopulmonary resuscitation (CPR) if necessary
Notify a Medic 6. BE AWARE. The field protective mask for Nuclear-Biological-Chemical (NBC) protection will not protect you from carbon monoxide poisoning.
TM 9-2320-272-23-4

HAZARDOUS MATERIALS DESCRIPTIONS - Continued
WARNING
CHEMICAL AGENT RESISTANT COATING (CARC) PAINT Chemical Agent Resistant Coating (CARC) paint contains isocyanate which is highly irritating to skin and respiratory system. High concentrations of isocyanate can produce symptoms of itching and reddening of skin, a burning sensation in the throat and nose, and watering of the eyes. In extreme concentrations, isocyanate can cause cough, shortness of breath, pain during respiration, increased sputum production, and chest tightness. First aid for ingestion: do not induce vomiting. Seek immediate medical attention. First aid fro skin contact: remove contaminated clothing. Wash skin thoroughly with soap and water. if symptoms persist, seek medical attention. First aid for inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention. Failure to comply may result in injury or death to personnel.
TM 9-2320-272-23-4

WARNING
SOLVENT CLEANING COMPOUND Solvent cleaning compound MIL-PRF-680 type II and III may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well ventilated areas. Use respirator as needed. Accidental ingestion can cause irritation of digestive tract and repository tract, and may cause lung and central nervous system damage. Can be fatal if swallowed. First aid for ingestion: do not induce vomiting. Seek immediate medical attention. First aid for skin contact: remove contaminated clothing, Wash skin thoroughly with soap and water. If symptoms persist, seek medical attention. First aid for eye contact: flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention. Inhalation of high/massive concentrations can cause coma or be fatal. First aid for inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention. Keep away from open flames and other sources of ignition. Failure to comply may result in injury or death to personnel. The flash point for type II solvent cleaning compound is 141F to 198F (61C to 92C) and type III is 200F to 241F (93C to 116C). Fire extinguishers should be placed nearby when using solvent cleaning compound. Improper cleaning methods and use of unauthorized cleaning solvents may injure personnel and damage equipment. Cloths or rags saturated with solvent cleaning compound must be disposed of using authorized facilities procedures. Eye shields must be worn when cleaning with a wire brush. Flying rust and metal particles may cause injury.
TM 9-2320-272-23-4

WARNING
LUBRICATING OIL Prolonged contact with lubricating oil may cause skin rash. Remove saturated clothing immediately and wash skin thoroughly that comes in contact with lubricating oil. Failure to comply may result in injury or death to personnel. Spilled hydraulic oil is slippery and creates a hazardous condition. Clean up and properly dispose of hydraulic oil. Failure to comply may result in injury or death to personnel.
WARNING
NUCLEAR, BIOLOGICAL, OR CHEMICAL If Nuclear, Biological, or Chemical (NBC) exposure is suspected, all filter media should be handled by personnel wearing protective equipment. Consult your unit NBC Officer or NBC NCO for appropriate handling or disposal instructions. Failure to comply may result in injury or death to personnel.
TM 9-2320-272-23-4

WARNING
LEAD-ACID BATTERIES Avoid battery electrolyte contact with skin, eyes, and clothing. If battery electrolyte spills, take the following immediate action to stop burning effects: External - If battery electrolyte contacts skin, immediately flush affected area with cold running water. Failure to comply may result in injury or death to personnel. Eyes - If battery electrolyte contacts eyes, immediately flush eyes with cold water for 15 minutes and seek immediate medical attention. IMPORTANT - If only one eye is affected, ensure the affected eye is always kept lower then the unaffected eye, during both flushing and transport. This will keep the the affected eye from draining into and contaminating the unaffected eye. Failure to comply may result in injury or death to personnel. Internal - If battery electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magnesia, a beaten egg or vegetable oil and seek immediate medical attention. Failure to comply may result in injury or death to personnel. Clothing or vehicle - immediately flush area with cold water and neutralize battery electrolyte with baking soda or household ammonia solution. Failure to comply may result in injury or death to personnel. Batteries produce explosive gases. Do not smoke or use open flame near batteries. Do not allow hot, parking or glowing objects near batteries. If batteries are giving off gases, the presence of heat, flame, or spark may cause fire and/or explosion. Failure to comply may result in injury or death to personnel. Wear proper eye protection, gloves, and an apron when working near batteries. Failure to comply may result in injury or death to personnel.
TM 9-2320-272-23-4

WARNING
DIESEL FUEL Diesel fuel is highly flammable and can be accidentally ignited. Do not smoke or allow open flame or sparks in the vicinity while working on any part of the fuel system. Keep fire extinguisher within easy reach when working with fuel. Failure to comply may result in injury or death to personnel. Spilled fuel is slippery and creates a hazardous condition. Clean up and properly disposed of spilled fuel as soon as possible. Failure to comply may result in injury or death to personnel. Do not work on fuel system when engine is hot. Failure to comply may result in injury or death to personnel. Safety glassed must be worn when working on pressurized systems. Failure to comply may result in injury or death to personnel.
WARNING
ADHESIVES AND SEALANTS Adhesives and sealants are flammable, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in a well-ventilated area. If adhesive or sealant contacts eye, flush with large amounts of water, and seek medical attention. If adhesive or sealant get on skin or clothing, flush with large amounts of water. If irritation persists, seek medical attention. Failure to comply may result in serious injury or death to personnel.
TM 9-2320-272-23-4
LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE: * Supersedes TM 9-2320-272-24-1, TM 9-2320-272-24-2, TM 9-2320-272-24-3, TM 9-2320-272-24-4 and TO 36A12-1C-1155-2-1, TO 36A12-1C-1155-2-2, TO 36A12-1C-1155-2-3, & TO 36A12-1C-1155-2-4, dated 30 June 1998. Zero in the Change No. Column indicates an original page or work package. Date of issue for the original manual is: Original 10 September 2012 TOTAL NUMBER OF VOLUMES IS 5, TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 71 AND TOTAL NUMBER OF WORK PACKAGES IS 216 CONSISTING OF THE FOLLOWING: Page/WP No. VOLUME 4 Front Cover (2 pages) WARNING SUMMARY (10 pages) i-xxxvii/xxxviii blank (38 page) Chapter 9 Title Page WP 0554 (4 pages) WP 0555 (4 pages) WP 0556 (4 pages) WP 0557 (2 pages) WP 0558 (6 pages) WP 0559 (18 pages) WP 0560 (4 pages) WP 0561 (2 pages) WP 0562 (4 pages) WP 0563 (2 pages) WP 0564 (2 pages) WP 0565 (12 pages) WP 0566 (2 pages) WP 0567 (6 pages) WP 0568 (6 pages) WP 0569 (4 pages) WP 0570 (4 pages) WP 0571 (4 pages) WP 0572 (4 pages) WP 0573 (4 pages) WP 0574 (4 pages) WP 0575 (4 pages) WP 0576 (10 pages) WP 0577 (4 pages) WP 0578 (6 pages) WP 0579 (4 pages) WP 0580 (4 pages) WP 0581 (6 pages) WP 0582 (14 pages) WP 0583 (4 pages) WP 0584 (4 pages) WP 0585 (4 pages) WP 0586 (6 pages) WP 0587 (4 pages) WP 0588 (10 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Page/WP No. WP 0589 (4 pages) WP 0590 (6 pages) WP 0591 (6 pages) WP 0592 (6 pages) WP 0593 (4 pages) WP 0594 (8 pages) WP 0595 (8 pages) WP 0596 (2 pages) WP 0597 (4 pages) WP 0598 (2 pages) WP 0599 (2 pages) WP 0600 (4 pages) WP 0601 (10 pages) WP 0602 (6 pages) WP 0603 (8 pages) WP 0604 (6 pages) WP 0605 (8 pages) WP 0606 (2 pages) WP 0607 (4 pages) WP 0608 (4 pages) WP 0609 (4 pages) WP 0610 (2 pages) WP 0611 (4 pages) WP 0612 (4 pages) WP 0613 (4 pages) WP 0614 (6 pages) WP 0615 (4 pages) WP 0616 (4 pages) WP 0617 (4 pages) WP 0618 (2 pages) WP 0619 (2 pages) WP 0620 (4 pages) WP 0621 (6 pages) WP 0622 (2 pages) WP 0623 (4 pages) WP 0624 (2 pages) WP 0625 (4 pages) WP 0626 (4 pages) WP 0627 (6 pages) WP 0628 (4 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
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LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued

Page/WP No. WP 0629 (6 pages) WP 0630 (16 pages) WP 0631 (6 pages) WP 0632 (10 pages) WP 0633 (6 pages) WP 0634 (4 pages) WP 0635 (6 pages) WP 0636 (6 pages) WP 0637 (6 pages) WP 0638 (4 pages) WP 0639 (32 pages) WP 0640 (4 pages) WP 0641 (6 pages) WP 0642 (4 pages) WP 0643 (4 pages) WP 0644 (2 pages) WP 0645 (6 pages) WP 0646 (4 pages) WP 0647 (6 pages) WP 0648 (4 pages) WP 0649 (2 pages) WP 0650 (10 pages) WP 0651 (10 pages) WP 0652 (10 pages) WP 0653 (6 pages) WP 0654 (6 pages) WP 0655 (8 pages) WP 0656 (6 pages) WP 0657 (6 pages) WP 0658 (12 pages) WP 0659 (6 pages) WP 0660 (10 pages) WP 0661 (6 pages) WP 0662 (4 pages) WP 0663 (6 pages) WP 0664 (4 pages) WP 0665 (4 pages) WP 0666 (6 pages) WP 0667 (6 pages) WP 0668 (6 pages) WP 0669 (2 pages) WP 0670 (10 pages) WP 0671 (6 pages) WP 0672 (4 pages) WP 0673 (4 pages) WP 0674 (2 pages) WP 0675 (8 pages) WP 0676 (8 pages) WP 0677 (8 pages) WP 0678 (16 pages) WP 0679 (10 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Page/WP No. WP 0680 (6 pages) WP 0681 (6 pages) WP 0682 (10 pages) WP 0683 (4 pages) WP 0684 (6 pages) WP 0685 (14 pages) WP 0686 (6 pages) WP 0687 (6 pages) WP 0688 (6 pages) WP 0689 (14 pages) WP 0690 (6 pages) WP 0691 (4 pages) WP 0692 (8 pages) WP 0693 (6 pages) WP 0694 (6 pages) WP 0695 (6 pages) WP 0696 (22 pages) WP 0697 (4 pages) WP 0698 (18 pages) WP 0699 (6 pages) WP 0700 (6 pages) WP 0701 (6 pages) WP 0702 (12 pages) WP 0703 (10 pages) WP 0704 (6 pages) WP 0705 (4 pages) WP 0706 (6 pages) WP 0707 (10 pages) WP 0708 (4 pages) WP 0709 (8 pages) WP 0710 (4 pages) WP 0711 (6 pages) WP 0712 (6 pages) WP 0713 (8 pages) WP 0714 (4 pages) WP 0715 (10 pages) WP 0716 (6 pages) WP 0717 (12 pages) WP 0718 (4 pages) WP 0719 (2 pages) WP 0720 (2 pages) WP 0721 (6 pages) WP 0722 (10 pages) WP 0723 (4 pages) WP 0724 (8 pages) WP 0725 (24 pages) WP 0726 (6 pages) WP 0727 (6 pages) WP 0728 (10 pages) WP 0729 (6 pages) WP 0730 (6 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
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LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued

Page/WP No. WP 0731 (4 pages) WP 0732 (4 pages) WP 0733 (2 pages) WP 0734 (2 pages) WP 0735 (6 pages) WP 0736 (6 pages) WP 0737 (8 pages) WP 0738 (6 pages) WP 0739 (6 pages) WP 0740 (2 pages) WP 0741 (4 pages) WP 0742 (4 pages) WP 0743 (4 pages) WP 0744 (2 pages) WP 0745 (6 pages) WP 0746 (6 pages) WP 0747 (6 pages) WP 0748 (6 pages) WP 0749 (2 pages) WP 0750 (6 pages) WP 0751 (4 pages) WP 0752 (6 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Page/WP No. WP 0753 (4 pages) WP 0754 (6 pages) WP 0755 (6 pages) WP 0756 (4 pages) WP 0757 (12 pages) WP 0758 (6 pages) WP 0759 (4 pages) WP 0760 (6 pages) WP 0761 (6 pages) WP 0762 (6 pages) WP 0763 (6 pages) WP 0764 (6 pages) WP 0765 (6 pages) WP 0766 (4 pages) WP 0767 (4 pages) WP 0768 (6 pages) WP 0769 (10 pages) WP 0770 (10 pages) Index-1 - Index-6 (6 pages) Inside Back Cover Back Cover Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
C/D blank
*TM 9-2320-272-23-4 *TO 36A12-1C-1155-2-4
HEADQUARTERS DEPARTMENTS OF THE ARMY AND THE AIR FORCE WASHINGTON, D.C., 10 SEPTEMBER 2012 TECHNICAL MANUAL FIELD MAINTENANCE MANUAL FOR
TRUCK, 5-TON, 6X6, M939, M939A1, AND M939A2 SERIES TRUCKS (DIESEL)
TRUCK, CARGO: 5-TON, 6X6 DROPSIDE
NSN NSN NSN NSN NSN NSN M923 2320-01-050-2084 M923A1 2320-01-206-4087 M923A2 2320-01-230-0307 M925 2320-01-047-8769 M925A1 2320-01-206-4088 M925A2 2320-01-230-0308 (EIC BRY) (EIC BSS) (EIC BS7) (EIC BRT) (EIC BST) (EIC BS8)
TRUCK, DUMP: 5-TON, 6X6

NSN NSN NSN NSN NSN NSN M929 2320-01-047-8756 M929A1 2320-01-206-4079 M929A2 2320-01-230-0305 M930 2320-01-047-8755 M930A1 2320-01-206-4080 M930A2 2320-01-230-0306 (EIC BTH) (EIC BSY) (EIC BT N) (EIC BTG) (EIC BSZ) (EIC BT7 )
TRUCK, VAN, EXPANSIBLE: 5-TON, 6X6

M934 NSN 2320-01-047-8750 (EIC BTB) M934A1 NSN 2320-01-205-2682 (EIC BS4) M934A2 NSN 2320-01-230-0300 (EIC BTR)
TRUCK, MEDIUM WRECKER: 5-TON, 6X6

M936 NSN 2320-01-047-8754 (EIC BTF) M936A1 NSN 2320-01-206-4078 (EIC BS6) M936A2 NSN 2320-01-230-0304 (EIC BTT)
M927 NSN 2320-01-047-8771 (EIC BRV) M927A1 NSN 2320-01-206-4089 (EIC BSW) M927A2 NSN 2320-01-230-0309 (EIC BS9) M928 NSN 2320-01-047-8770 (EIC BRU) M928A1 NSN 2320-01-206-4090 (EIC BSX) M928A2 NSN 2320-01-230-0310 (EIC BTM)
TRUCK, CARGO: 5-TON, 6X6 XLWB
M931 NSN 2320-01-047-8753 M931A1 NSN 2320-01-206-4077 M931A2 NSN 2320-01-230-0302 M932 NSN 2320-01-047-8752 M932A1 NSN 2320-01-205-2684 M932A2 NSN 2320-01-230-0303
TRUCK, TRACTOR: 5-TON, 6X6

(EIC BTE) (EIC BS2 ) (EIC BTP ) (EIC BTD ) (EIC BSZ) (EIC BTQ )
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication. If you find any mistakes, or if you know of a way to improve the procedures, please let us know: Reports, as applicable by the requiring service, should be submitted as follows: (A ) Army - Mail your letter or DA Form 2028 (Recommended Changes to Publications and Blank Forms), located in the back of this manual directly to: U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP/ TECH PUBS, MS 727, 6501 E. 11 Mile Road, Warren, MI 48397-5000. You may also send in your recommended changes via electronic mail or by fax. Our fax number is DSN 786-1856 or Commercial (586) 282-1856. Our email address is tacomlcmc.daform2028@us.army.mil. (F) Air Force - By Air Force AFTO Form 22 directly to WR/ALC/GRVEB, Robins GA. You may also send in your recommended changes electronically via email. Email AFTO form 22 to robins.ce.afto22@robins.af.mil. A reply will be furnished to you.
*SUPERSEDURE NOTICE: This manual supersedes TM 9-2320-272-24-1, TM 9-2320-272-24-2, TM 9-2320-272-24-3, TM 9-2320-272-24-4, TO 36A12-1C-1155-2-1, TO 36A12-1C-1155-2-2, TO 36A12-1C-1155-2-3, TO 36A12-1C-1155-2-4, dated 30 June 1998, including all changes. DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.
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TABLE OF CONTENTS
Page No. WP Sequence No. Volume 4 Chapter 9 - MAINTENANCE INSTRUCTIONS WINDOW BLACKOUT PANEL REPLACEMENT........................................................................................ WP 0554 Figure 1. Figure 2. Window Blackout Panel Removal........................................................................................ 0554-2 Window Blackout Panel Installation..................................................................................... 0554-3
CAB DOOR CHECK ROD REPLACEMENT............................................................................................... WP 0555 Figure 1. Figure 2. Cab Door Check Rod Removal............................................................................................ 0555-2 Cab Door Check Rod Installation......................................................................................... 0555-3
CAB DOOR HINGE REPLACEMENT......................................................................................................... WP 0556 Figure 1. Figure 2. Cab Door Hinge Removal.................................................................................................... 0556-2 Cab Door Hinge Installation................................................................................................. 0556-3
CAB DOOR CATCH REPLACEMENT........................................................................................................ WP 0557 Figure 1. Figure 2. Cab Door Catch Removal.................................................................................................... 0557-1 Cab Door Catch Installation................................................................................................. 0557-2
HOOD LATCH AND BRACKET REPLACEMENT....................................................................................... WP 0558 Figure 1. Figure 2. Hood Latch & Bracket Removal........................................................................................... 0558-3 Hood Latch & Bracket Installation........................................................................................ 0558-5
HOOD SUPPORT BAR BRACKET, CROSSMEMBER, HINGES, AND TORSION BARS REPLACEMENT.......................................................................................................................................... WP 0559 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Hood Support Bar and Bracket Removal............................................................................. 0559-3 Hood Support Bar and Bracket Installation.......................................................................... 0559-4 Hood Retaining Bracket Replacement................................................................................. 0559-5 Hood Crossmember Bracket Removal................................................................................. 0559-6 Hood Crossmember Bracket Cleaning and Inspection........................................................ 0559-7 Hood Crossmember Bracket Installation.............................................................................. 0559-9 Hood Hinge Removal......................................................................................................... 0559-11 Hood Hinge Installation...................................................................................................... 0559-13 Torsion Bars and Crossmembers Removal....................................................................... 0559-15
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TABLE OF CONTENTS - Continued

Page No. WP Sequence No. Figure 10. Torsion Bars and Crossmembers Installation.................................................................... 0559-17
HOOD STOP CABLES REPLACEMENT.................................................................................................... WP 0560 Figure 1. Figure 2. Hood Stop Cables Removal................................................................................................. 0560-2 Hood Stop Cables Installation.............................................................................................. 0560-3
HOOD GRAB HANDLE REPLACEMENT................................................................................................... WP 0561 Figure 1. Figure 2. Hood Grab Handle Removal................................................................................................ 0561-1 Hood Grab Handle Installation............................................................................................. 0561-2
RADIATOR BAFFLES, SEALS, AND PLATES REPLACEMENT............................................................... WP 0562 Figure 1. Figure 2. Radiator Baffles, Seals, and Plates Removal....................................................................... 0562-2 Radiator Baffles, Seals, and Plates Installation.................................................................... 0562-3
CAB HOOD STOP BRACKET REPLACEMENT......................................................................................... WP 0563 Figure 1. Figure 2. Cab Hood Stop Bracket Removal........................................................................................ 0563-1 Cab Hood Stop Bracket Installation..................................................................................... 0563-2
HOOD BUMPER REPLACEMENT.............................................................................................................. WP 0564 Figure 1. Figure 2. Hood Bumper Removal........................................................................................................ 0564-1 Hood Bumper Installation..................................................................................................... 0564-2
ENGINE HOOD REPLACEMENT............................................................................................................... WP 0565 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Engine Hood Removal......................................................................................................... 0565-3 Engine Hood Removal......................................................................................................... 0565-5 Engine Hood Installation...................................................................................................... 0565-7 Engine Hood Installation...................................................................................................... 0565-9 Engine Hood Adjustment.................................................................................................... 0565-11
WINDSHIELD STOP BRACKET AND LATCH REPLACEMENT................................................................ WP 0566 Figure 1. Figure 2. Windshield Stop Bracket and Latch Removal...................................................................... 0566-1 Windshield Stop Bracket and Latch Installation................................................................... 0566-2
ENGINE ACCESS COVER (IN-CAB) REPLACEMENT.............................................................................. WP 0567 Figure 1. Engine Access Cover (In-Cab) Removal.............................................................................. 0567-3
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Page No. WP Sequence No. Figure 2. Engine Access Cover (In-Cab) Installation........................................................................... 0567-5
FRONT CAB MOUNT REPLACEMENT...................................................................................................... WP 0568 Figure 1. Figure 2. Front Cab Mount Removal................................................................................................... 0568-3 Front Cab Mount Installation................................................................................................ 0568-5
REAR CAB MOUNT REPLACEMENT........................................................................................................ WP 0569 Figure 1. Figure 2. Rear Cab Mount Removal.................................................................................................... 0569-2 Rear Cab Mount Installation................................................................................................. 0569-3
CAB GRAB HANDLE REPLACEMENT....................................................................................................... WP 0570 Figure 1. Figure 2. Cab Grab Handle Removal.................................................................................................. 0570-2 Cab Grab Handle Installation............................................................................................... 0570-3
VENT DOOR WEATHER SEAL REPLACEMENT...................................................................................... WP 0571 Figure 1. Figure 2. Vent Door Weather Seal Removal....................................................................................... 0571-2 Vent Door Weather Seal Installation.................................................................................... 0571-3
CAB COWL VENT SCREEN AND DOOR REPLACEMENT....................................................................... WP 0572 Figure 1. Figure 2. Cab Cowl Vent Screen & Door Removal.............................................................................. 0572-2 Cab Cowl Vent Screen & Door Installation........................................................................... 0572-3
FRONT FENDERS REPLACEMENT.......................................................................................................... WP 0573 Figure 1. Figure 2. Front Fender Removal......................................................................................................... 0573-2 Front Fender Installation...................................................................................................... 0573-3
FRONT FENDER EXTENSION REPLACEMENT....................................................................................... WP 0574 Figure 1. Figure 2. Front Fender Extension Removal......................................................................................... 0574-2 Front Fender Extension Installation...................................................................................... 0574-3
FENDER SPLASH SHIELD REPLACEMENT............................................................................................. WP 0575 Figure 1. Figure 2. Fender Splash Shield Removal............................................................................................ 0575-2 Fender Splash Shield Installation......................................................................................... 0575-3
RADIATOR BRUSHGUARD REPLACEMENT............................................................................................ WP 0576 Figure 1. Radiator Brushguard Removal............................................................................................. 0576-3
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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Radiator Brushguard Removal............................................................................................. 0576-4 Radiator Brushguard Removal............................................................................................. 0576-5 Radiator Brushguard Installation.......................................................................................... 0576-6 Radiator Brushguard Installation.......................................................................................... 0576-7 Radiator Brushguard Installation.......................................................................................... 0576-9
WINDSHIELD AND OUTER FRAME ASSEMBLY REPLACEMENT.......................................................... WP 0577 Figure 1. Figure 2. Windshield and Outer Frame Assembly Removal................................................................ 0577-2 Windshield and Outer Frame Assembly Installation............................................................. 0577-3
WINDSHIELD FRAME ASSEMBLY REPLACEMENT................................................................................ WP 0578 Figure 1. Figure 2. Figure 3. Figure 4. Windshield Frame Removal................................................................................................. 0578-2 Cab Windshield Disassembly............................................................................................... 0578-3 Cab Windshield Assembly.................................................................................................... 0578-4 Windshield Frame Installation.............................................................................................. 0578-5
CAB WINDSHIELD HINGE ASSEMBLY REPLACEMENT......................................................................... WP 0579 Figure 1. Figure 2. Cab Windshield Hinge Removal........................................................................................... 0579-2 Cab Windshield Hinge Installation........................................................................................ 0579-3
CAB INSULATION REPLACEMENT........................................................................................................... WP 0580 Figure 1. Figure 2. Cab Insulation Removal....................................................................................................... 0580-2 Cab Insulation Installation.................................................................................................... 0580-3
COMPANION SEAT CUSHION, BACKREST CUSHION, AND FRAME REPLACEMENT......................... WP 0581 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Companion Seat Cushion, Backrest Cushion, and Frame Removal.................................... 0581-1 Companion Seat Cushion, Backrest Cushion, and Frame Removal.................................... 0581-2 Companion Seat Cushion, Backrest Cushion, and Frame Removal.................................... 0581-3 Companion Seat Cushion, Backrest Cushion, and Frame Installation................................. 0581-4 Companion Seat Cushion, Backrest Cushion, and Frame Installation................................. 0581-5 Companion Seat Cushion, Backrest Cushion, and Frame Installation................................. 0581-6
DRIVER'S SEAT, FRAME, AND BASE REPLACEMENT........................................................................... WP 0582
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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Driver's Seat Removal.......................................................................................................... 0582-3 Driver's Seat Installation....................................................................................................... 0582-5 Driver's Seat Frame and Base Removal.............................................................................. 0582-7 Driver's Seat Frame and Base............................................................................................. 0582-9 Driver's Seat and Frame Installation.................................................................................. 0582-11 Driver's Seat Frame and Base Installation......................................................................... 0582-13
DRIVER'S SEAT CUSHION AND BACKREST CUSHION REPLACEMENT.............................................. WP 0583 Figure 1. Figure 2. Figure 3. Figure 4. Driver's Seat Cushion and Backrest Cushion Removal....................................................... 0583-1 Driver's Seat Cushion and Backrest Cushion Removal....................................................... 0583-2 Driver's Seat Cushion and Backrest Cushion Installation.................................................... 0583-3 Driver's Seat Cushion and Backrest Cushion Installation.................................................... 0583-4
MAP COMPARTMENT REPLACEMENT.................................................................................................... WP 0584 Figure 1. Figure 2. Map Compartment Removal................................................................................................ 0584-2 Map Compartment Installation............................................................................................. 0584-3
VAN POWER CABLE REEL REPLACEMENT (M934A1/A2)...................................................................... WP 0585 Figure 1. Figure 2. Van Power Cable Reel Removal.......................................................................................... 0585-2 Van Power Cable Reel Installation....................................................................................... 0585-3
TOOLBOX AND STEPS REPLACEMENT.................................................................................................. WP 0586 Figure 1. Figure 2. Toolbox and Steps Removal................................................................................................ 0586-3 Toolbox and Steps Installation............................................................................................. 0586-5
CARGO STOWAGE BOX REPLACEMENT................................................................................................ WP 0587 Figure 1. Figure 2. Cargo Stowage Removal..................................................................................................... 0587-2 Cargo Stowage Installation.................................................................................................. 0587-3
CARGO BODY ASSEMBLY REPAIR.......................................................................................................... WP 0588 Figure 1. Figure 2. Figure 3. Front Holddown Brackets..................................................................................................... 0588-2 Intermediate Holddown Brackets......................................................................................... 0588-3 Cargo Body Removal........................................................................................................... 0588-5
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Page No. WP Sequence No. Figure 4. Figure 5. Cargo Body.......................................................................................................................... 0588-7 Cargo Body.......................................................................................................................... 0588-9
CARGO TROOP SEAT REPAIR................................................................................................................. WP 0589 Figure 1. Figure 2. Cargo Troop Seat Removal.................................................................................................. 0589-2 Cargo Troop Seat Installation............................................................................................... 0589-3
CARGO TAILGATE AND BUMPER REPLACEMENT................................................................................ WP 0590 Figure 1. Figure 2. Cargo Tailgate and Bumper Removal.................................................................................. 0590-3 Cargo Tailgate and Bumper Installation............................................................................... 0590-5
DUMP TAILGATE CONTROL LINKAGE REPLACEMENT......................................................................... WP 0591 Figure 1. Figure 2. Dump Tailgate Control Linkage Removal............................................................................. 0591-3 Dump Tailgate Control Linkage Installation.......................................................................... 0591-5
DUMP TAILGATE ASSEMBLY REPLACEMENT........................................................................................ WP 0592 Figure 1. Figure 2. Dump Tailgate Assembly Removal...................................................................................... 0592-3 Dump Tailgate Assembly Installation................................................................................... 0592-5
CARGO BODY FRAME RAIL SILL REPLACEMENT.................................................................................. WP 0593 Figure 1. Figure 2. Figure 3. Figure 4. Frame Rail Sill Removal....................................................................................................... 0593-1 Cargo Frame Fabrication..................................................................................................... 0593-2 Cargo Frame Fabrication..................................................................................................... 0593-3 Frame Rail Sill Installation.................................................................................................... 0593-4
DUMP BODY REPAIR................................................................................................................................. WP 0594 Figure 1. Figure 2. Figure 3. Dump Body Removal........................................................................................................... 0594-3 Dump Body Installation........................................................................................................ 0594-5 Dump Body Installation........................................................................................................ 0594-7
DUMP CAB PROTECTOR SHIELD REPAIR.............................................................................................. WP 0595 Figure 1. Figure 2. Figure 3. Dump Cab Protector Shield Removal.................................................................................. 0595-2 Dump Cab Protector Shield Removal.................................................................................. 0595-3 Dump Cab Protector Shield Removal.................................................................................. 0595-4
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Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Dump Cab Protector Shield Installation............................................................................... 0595-5 Dump Cab Protector Shield Installation............................................................................... 0595-6 Dump Cab Protector Shield Installation............................................................................... 0595-7
CARGO UPPER WHEEL SPLASH GUARD REPLACEMENT................................................................... WP 0596 Figure 1. Figure 2. Upper Wheel Splash Guard Removal.................................................................................. 0596-1 Upper Wheel Splash Guard Installation............................................................................... 0596-2
SIDE LOCKING PIN RETAINING CLIP REPLACEMENT........................................................................... WP 0597 Figure 1. Figure 2. Side Locking Pin Retaining Clip Removal............................................................................ 0597-2 Side Locking Pin Retaining Clip Installation......................................................................... 0597-3
TAILGATE PERSONNEL STEP REPLACEMENT...................................................................................... WP 0598 Figure 1. Tailgate Personnel Step Replacement................................................................................. 0598-2
VAN REAR DOOR AND SIDE DOOR WINDOW REPLACEMENT............................................................ WP 0599 Figure 1. Van Rear Door and Side Door Window Replacement......................................................... 0599-1
WINDOW BRUSH GUARD REPLACEMENT.............................................................................................. WP 0600 Figure 1. Figure 2. Window Brush Guard Removal............................................................................................ 0600-2 Window Brush Guard Installation......................................................................................... 0600-3
REAR DOOR REPAIR................................................................................................................................. WP 0601 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Rear Door Removal.............................................................................................................. 0601-2 Rear Door Disassembly....................................................................................................... 0601-3 Rear Door Disassembly....................................................................................................... 0601-4 Rear Door Disassembly....................................................................................................... 0601-5 Rear Door Assembly............................................................................................................ 0601-7 Rear Door Assembly............................................................................................................ 0601-8 Rear Door Assembly............................................................................................................ 0601-9 Rear Door Installation......................................................................................................... 0601-10
VAN SIDE DOORS MAINTENANCE........................................................................................................... WP 0602 Figure 1. Side Doors Removal............................................................................................................ 0602-3
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Page No. WP Sequence No. Figure 2. Side Doors Installation......................................................................................................... 0602-4
VAN HINGED END PANEL REPAIR........................................................................................................... WP 0603 Figure 1. Figure 2. Figure 3. Figure 4. Hinged End Panel Removal................................................................................................. 0603-3 Hinged End Panel Disassembly........................................................................................... 0603-5 Hinged End Panel Assembly................................................................................................ 0603-7 Hinged End Panel Installation.............................................................................................. 0603-8
VAN HINGED ROOF AND FLOOR COUNTERBALANCE CABLE REPLACEMENT................................. WP 0604 Figure 1. Figure 2. Figure 3. Figure 4. Hinge Roof and Floor Counterbalance Cable Removal....................................................... 0604-2 Hinge Roof and Floor Counterbalance Cable Removal....................................................... 0604-3 Hinge Roof and Floor Counterbalance Cable Installation.................................................... 0604-5 Hinge Roof and Floor Counterbalance Cable Installation.................................................... 0604-6
VAN RETRACTABLE WINDOW REPLACEMENT...................................................................................... WP 0605 Figure 1. Figure 2. Figure 3. Figure 4. Retractable Window Removal.............................................................................................. 0605-2 Retractable Window Installation........................................................................................... 0605-3 Window Glass Removal....................................................................................................... 0605-5 Window Glass Installation.................................................................................................... 0605-7
VAN WINDOW SCREEN REPLACEMENT................................................................................................. WP 0606 Figure 1. Window Screen Replacement.............................................................................................. 0606-2
VAN RETRACTABLE WINDOW REGULATOR REPLACEMENT.............................................................. WP 0607 Figure 1. Figure 2. Retractable Window Regulator Removal............................................................................. 0607-2 Retractable Window Regulator Installation.......................................................................... 0607-3
WINDOW REGULATOR AND INSIDE DOOR HANDLE REPLACEMENT................................................. WP 0608 Figure 1. Figure 2. Window Removal................................................................................................................. 0608-2 Window Installation.............................................................................................................. 0608-3
VAN SIDE PANEL-TO-ROOF TOGGLE CLAMP REPLACEMENT............................................................ WP 0609 Figure 1. Figure 2. Side Panel-to-Roof Toggle Clamp Removal........................................................................ 0609-2 Side Panel-to-Roof Toggle Clamp Installation..................................................................... 0609-3
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Page No. WP Sequence No. VAN TOGGLE CLAMP ANCHOR POST REPLACEMENT......................................................................... WP 0610 Figure 1. Toggle Clamp Anchor Post Replacement............................................................................ 0610-2
VAN SIDE PANEL ROOF SWIVEL HOOK REPLACEMENT...................................................................... WP 0611 Figure 1. Figure 2. Side Panel Roof Swivel Hook Removal............................................................................... 0611-2 Side Panel Roof Swivel Hook Installation............................................................................ 0611-3
VAN LADDER LOCKING CLAMP REPLACEMENT................................................................................... WP 0612 Figure 1. Figure 2. Ladder Locking Clamp Removal.......................................................................................... 0612-2 Ladder Locking Clamp Installation....................................................................................... 0612-3
VAN BONNET HANDLE AND CONTROL ROD REPLACEMENT.............................................................. WP 0613 Figure 1. Figure 2. Bonnet Handle and Control Rod Removal........................................................................... 0613-2 Bonnet Handle and Control Rod Installation........................................................................ 0613-3
VAN DOOR HINGE AND SEAL REPLACEMENT....................................................................................... WP 0614 Figure 1. Figure 2. Door Hinge and Seal Removal............................................................................................. 0614-3 Door Hinge and Seal Installation.......................................................................................... 0614-5
VAN PANEL SEALS REPLACEMENT........................................................................................................ WP 0615 Figure 1. Figure 2. Panel Seals Removal........................................................................................................... 0615-2 Panel Seals Installation........................................................................................................ 0615-3
VAN DOOR HANDLE AND LOCK REPLACEMENT................................................................................... WP 0616 Figure 1. Figure 2. Door Handle and Lock Removal.......................................................................................... 0616-2 Door Handle and Lock Installation....................................................................................... 0616-3
VAN DOOR CHECKS REPLACEMENT...................................................................................................... WP 0617 Figure 1. Figure 2. Door Checks Removal......................................................................................................... 0617-2 Door Checks Installation...................................................................................................... 0617-3
VAN LADDER RACK BUMPERS REPLACEMENT.................................................................................... WP 0618 Figure 1. Ladder Rack Bumpers Replacement................................................................................... 0618-1
VAN SIDE PANEL RUBBER BUMPERS REPLACEMENT......................................................................... WP 0619 Figure 1. Side Panel Rubber Bumper Replacement........................................................................... 0619-1
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Page No. WP Sequence No. VAN SIDE PANEL REAR LOCK REPLACEMENT...................................................................................... WP 0620 Figure 1. Figure 2. Side Panel Rear Lock Removal........................................................................................... 0620-2 Side Panel Rear Lock Installation........................................................................................ 0620-3
VAN SIDE PANEL FRONT LOCK AND HINGED-TYPE ROOF LOCK REPLACEMENT........................... WP 0621 Figure 1. Figure 2. Latch Assembly Removal..................................................................................................... 0621-3 Latch Assembly Installation.................................................................................................. 0621-5
VAN SIDE PANEL EXTERIOR LOCK REPLACEMENT............................................................................. WP 0622 Figure 1. Figure 2. Side Panel Exterior Lock Removal....................................................................................... 0622-1 Side Panel Exterior Lock Installation.................................................................................... 0622-2
VAN FLUORESCENT LIGHT TUBE REPLACEMENT................................................................................ WP 0623 Figure 1. Figure 2. Fluorescent Light Tube Removal......................................................................................... 0623-2 Fluorescent Light Tube Installation...................................................................................... 0623-3
VAN EMERGENCY/BLACKOUT LIGHT LAMP AND LENS REPLACEMENT............................................ WP 0624 Figure 1. Figure 2. Emergency/Blackout Light Lamp and Lens Removal........................................................... 0624-1 Emergency/Blackout Light Lamp and Lens Installation........................................................ 0624-2
VAN BLACKOUT LIGHT SWITCH AND 110-VOLT RECEPTACLE REPLACEMENT............................... WP 0625 Figure 1. Figure 2. Blackout Light Switch and 110-Volt Receptacle Removal.................................................... 0625-2 Blackout Light Switch and 110-Volt Receptacle Installation................................................. 0625-3
VAN INSIDE TELEPHONE JACK POST REPLACEMENT......................................................................... WP 0626 Figure 1. Figure 2. Inside Telephone Jack Post Removal.................................................................................. 0626-2 Inside Telephone Jack Post Installation............................................................................... 0626-3
VAN OUTSIDE TELEPHONE JACK POST REPLACEMENT..................................................................... WP 0627 Figure 1. Figure 2. Outside Telephone Jack Post Removal............................................................................... 0627-3 Outside Telephone Jack Post Installation............................................................................ 0627-5
VAN SIDE AND REAR DOOR BLACKOUT LIGHT SWITCH REPLACEMENT.......................................... WP 0628 Figure 1. Figure 2. Side and Rear Door Blackout Light Switch Removal........................................................... 0628-1 Side and Rear Door Blackout Light Switch Installation........................................................ 0628-2
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Page No. WP Sequence No. Figure 3. Side and Rear Door Blackout Light Adjustment................................................................... 0628-3
VAN HINGED ROOF-OPERATED BLACKOUT CIRCUIT PLUNGERS REPLACEMENT......................... WP 0629 Figure 1. Figure 2. Hinged Roof-Operated Blackout Circuit Plungers Removal................................................. 0629-3 Hinged Roof-Operated Blackout Circuit Plungers Installation.............................................. 0629-4
VAN RETRACTABLE BEAM ASSEMBLY REPLACEMENT....................................................................... WP 0630 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Retractable Beam Assembly Removal................................................................................. 0630-2 Retractable Beam Assembly Removal................................................................................. 0630-3 Retractable Beam Assembly Removal................................................................................. 0630-5 Retractable Beam Assembly Removal................................................................................. 0630-7 Retractable Beam Assembly Cleaning, Inspection, and Repair........................................... 0630-9 Retractable Beam Assembly Installation............................................................................ 0630-11 Retractable Beam Assembly Installation............................................................................ 0630-13 Retractable Beam Assembly Installation............................................................................ 0630-14 Retractable Beam Assembly Installation............................................................................ 0630-15
VAN HEATER AND EXHAUST REPLACEMENT....................................................................................... WP 0631 Figure 1. Figure 2. Van Heater and Exhaust Removal....................................................................................... 0631-3 Van Heater and Exhaust Installation.................................................................................... 0631-5
VAN HEATER FUEL PUMP REPLACEMENT (M934/A1/A2)..................................................................... WP 0632 Figure 1. Figure 2. Figure 3. Figure 4. Van Heater Fuel Pump Removal (M934A1/A2)................................................................... 0632-3 Van Heater Fuel Pump Installation (M934A1/A2)................................................................ 0632-5 Van Heater Fuel Pump Removal (M934)............................................................................. 0632-7 Van Heater Fuel Pump Installation (M934).......................................................................... 0632-8
AIR CONDITIONER DRAIN TUBE REPLACEMENT.................................................................................. WP 0633 Figure 1. Figure 2. Air Conditioner Drain Tube Removal.................................................................................... 0633-3 Air Conditioner Drain Tube Installation................................................................................. 0633-5
HEATER FUEL PUMP WIRING HARNESS REPLACEMENT.................................................................... WP 0634 Figure 1. Heater Fuel Pump Wiring Harness Removal....................................................................... 0634-1
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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Heater Fuel Pump Wiring Harness Removal....................................................................... 0634-2 Heater Fuel Pump Wiring Harness Installation.................................................................... 0634-3 Heater Fuel Pump Wiring Harness Installation.................................................................... 0634-4
RIGHT AND LEFT SIDE BLACKOUT HARNESS REPAIR......................................................................... WP 0635 Figure 1. Figure 2. Blackout Harness................................................................................................................. 0635-3 Blackout Harness................................................................................................................. 0635-4
CIRCUIT BREAKER HARNESS AND CIRCUIT BREAKER REPLACEMENT........................................... WP 0636 Figure 1. Figure 2. Circuit Breaker Harness and Circuit Breaker Removal........................................................ 0636-3 Circuit Breaker Harness and Circuit Breaker Installation..................................................... 0636-5
ENTRANCE RECEPTACLE 220V 3-PHASE WIRING HARNESS REPLACEMENT.................................. WP 0637 Figure 1. Figure 2. Entrance Receptacle Removal............................................................................................. 0637-3 Entrance Receptacle Installation.......................................................................................... 0637-5
FLEXIBLE CONVERTER WIRING HARNESS REPLACEMENT................................................................ WP 0638 Figure 1. Figure 2. Flexible Converter Wiring Harness Removal....................................................................... 0638-2 Flexible Converter Wiring Harness Installation.................................................................... 0638-3
ELECTRICAL LOAD CENTER BOX REPLACEMENT................................................................................ WP 0639 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Load Center Box.................................................................................................................. 0639-2 Load Center Box.................................................................................................................. 0639-3 Load Center Box.................................................................................................................. 0639-4 Load Center Box.................................................................................................................. 0639-5 Load Center Box.................................................................................................................. 0639-6 Load Center Box.................................................................................................................. 0639-7 Load Center Box.................................................................................................................. 0639-8 Load Center Box.................................................................................................................. 0639-9 Load Center Box................................................................................................................ 0639-10 Load Center Box................................................................................................................ 0639-11 Load Center Box................................................................................................................ 0639-12
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Page No. WP Sequence No. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Load Center Box................................................................................................................ 0639-13 Load Center Box................................................................................................................ 0639-15 Load Center Box................................................................................................................ 0639-17 Load Center Box................................................................................................................ 0639-19 Load Center Box................................................................................................................ 0639-20 Load Center Box................................................................................................................ 0639-21 Load Center Box................................................................................................................ 0639-22 Load Center Box................................................................................................................ 0639-23 Load Center Box................................................................................................................ 0639-24 Load Center Box................................................................................................................ 0639-25 Load Center Box................................................................................................................ 0639-26 Load Center Box................................................................................................................ 0639-27 Load Center Box................................................................................................................ 0639-28 Load Center Box................................................................................................................ 0639-29 Load Center Box................................................................................................................ 0639-30 Load Center Box................................................................................................................ 0639-31 Load Center Box................................................................................................................ 0639-32
ELECTRICAL BOX REPLACEMENT.......................................................................................................... WP 0640 Figure 1. Figure 2. Electrical Box Removal........................................................................................................ 0640-2 Electrical Box Installation..................................................................................................... 0640-3
ELECTRICAL JUNCTION BOX REPLACEMENT....................................................................................... WP 0641 Figure 1. Figure 2. Figure 3. Figure 4. Electrical Junction Box Removal.......................................................................................... 0641-2 Electrical Junction Box Removal.......................................................................................... 0641-3 Electrical Junction Box Installation....................................................................................... 0641-4 Electrical Junction Box Installation....................................................................................... 0641-5
400 HZ CONVERTER HARNESS CONDUIT REPLACEMENT.................................................................. WP 0642 Figure 1. Converter Harness Conduit Removal................................................................................... 0642-2
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Page No. WP Sequence No. Figure 2. Converter Harness Conduit Installation................................................................................ 0642-3
HEATER THERMOSTAT AND 10 KW HEATER THERMOSTAT REPLACEMENT................................... WP 0643 Figure 1. Figure 2. Figure 3. Figure 4. Heater Thermostat and 10 KW Heater Thermostat and 10 KW Heater Thermostat Removal............................................................................................................ 0643-1 Heater Thermostat and 10 KW Heater Thermostat and 10 KW Heater Thermostat Removal............................................................................................................ 0643-2 Heater Thermostat and 10 KW Heater Thermostat.............................................................. 0643-3 Heater Thermostat and 10 KW Heater Thermostat Installation........................................... 0643-4
BLACKOUT AND EMERGENCY LIGHT FIXTURES REPLACEMENT...................................................... WP 0644 Figure 1. Figure 2. Blackout and Emergency Light Fixtures Removal................................................................ 0644-1 Blackout and Emergency Light Fixtures Installation............................................................. 0644-2
AIR CONDITIONER MANUAL STARTER SWITCHES REPLACEMENT................................................... WP 0645 Figure 1. Figure 2. Figure 3. Figure 4. Air Conditioner Replacement............................................................................................... 0645-2 Air Conditioner Switch.......................................................................................................... 0645-3 Air Conditioner Switch.......................................................................................................... 0645-4 Air Conditioner Switch.......................................................................................................... 0645-5
FLUORESCENT LIGHT FIXTURES REPLACEMENT................................................................................ WP 0646 Figure 1. Figure 2. Fluorescent Light.................................................................................................................. 0646-2 Fluorescent Light.................................................................................................................. 0646-3
400 HZ CONVERTER REPLACEMENT...................................................................................................... WP 0647 Figure 1. Figure 2. 400 Hz Converter Removal.................................................................................................. 0647-3 400 Hz Converter Installation............................................................................................... 0647-5
ELECTRICAL LOAD CENTER CONDUIT REPLACEMENT....................................................................... WP 0648 Figure 1. Figure 2. Figure 3. Figure 4. Electrical Load Center Conduit Removal............................................................................. 0648-1 Electrical Load Center Conduit Removal............................................................................. 0648-2 Electrical Load Center Conduit Installation.......................................................................... 0648-3 Electrical Load Center Conduit Installation.......................................................................... 0648-4
FRONT WALL REGISTERS REPLACEMENT............................................................................................ WP 0649
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Page No. WP Sequence No. Figure 1. Figure 2. Front Wall Registers Removal.............................................................................................. 0649-1 Front Wall Registers Installation........................................................................................... 0649-2
BONNET ACCESS DOOR MAINTENANCE............................................................................................... WP 0650 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Bonnet Access Door Removal............................................................................................. 0650-3 Bonnet Access Door Disassembly....................................................................................... 0650-5 Bonnet Access Door Cleaning and Inspection..................................................................... 0650-7 Bonnet Access Door Assembly............................................................................................ 0650-9 Bonnet Access Door Installation........................................................................................ 0650-10
BONNET DOOR MAINTENANCE............................................................................................................... WP 0651 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Bonnet Door Removal.......................................................................................................... 0651-3 Bonnet Door Disassembly.................................................................................................... 0651-5 Bonnet Door Cleaning and Inspection.................................................................................. 0651-7 Bonnet Door Assembly......................................................................................................... 0651-9 Bonnet Door Installation..................................................................................................... 0651-10
AIR CONDITIONER REPAIR...................................................................................................................... WP 0652 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Air Conditioner Removal...................................................................................................... 0652-3 Air Conditioner Removal...................................................................................................... 0652-5 Air Conditioner Installation................................................................................................... 0652-7 Air Conditioner Installation................................................................................................... 0652-8 Air Conditioner Installation................................................................................................... 0652-9
MAIN WIRING HARNESS REPLACEMENT............................................................................................... WP 0653 Figure 1. Figure 2. Main Wiring Harness Removal............................................................................................. 0653-3 Main Wiring Harness Installation.......................................................................................... 0653-5
VAN AIR CONDITIONER WIRING HARNESS REPLACEMENT................................................................ WP 0654 Figure 1. Figure 2. Van Air Conditioner Wiring Harness Removal..................................................................... 0654-3 Van Air Conditioner Wiring Harness Installation.................................................................. 0654-5
VAN HEATER WIRING HARNESS REPLACEMENT................................................................................. WP 0655
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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Van Heater Wiring Harness Removal.................................................................................. 0655-3 Van Heater Wiring Harness Removal.................................................................................. 0655-5 Van Heater Wiring Harness Installation............................................................................... 0655-7 Van Heater Wiring Harness Installation............................................................................... 0655-8
ELECTRIC HEATER (10 KW) WIRING HARNESS REPLACEMENT......................................................... WP 0656 Figure 1. Figure 2. Electric Heater (10 Kw) Wiring Harness Removal................................................................ 0656-3 Electric Heater (10 Kw) Wiring Harness Installation............................................................. 0656-5
BLACKOUT BYPASS WIRING HARNESS REPAIR................................................................................... WP 0657 Figure 1. Figure 2. Blackout Bypass Wiring Harness Removal.......................................................................... 0657-3 Blackout Bypass Wiring Harness Installation....................................................................... 0657-5
EMERGENCY LAMP WIRING HARNESS REPLACEMENT...................................................................... WP 0658 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Emergency Lamp Wiring Harness Removal........................................................................ 0658-3 Emergency Wiring Harness Removal.................................................................................. 0658-5 Emergency Lamp Wiring Harness Installation..................................................................... 0658-7 Emergency Lamp Wiring Harness Installation..................................................................... 0658-9 Emergency Lamp Wiring Harness Installation................................................................... 0658-11
BLACKOUT AND CLEARANCE LIGHTS WIRING HARNESS REPLACEMENT....................................... WP 0659 Figure 1. Figure 2. Blackout and Clearance Lights Wiring Harness Removal.................................................... 0659-3 Blackout and Clearance Lights Wiring Harness Installation................................................. 0659-5
400 HZ SUPPLY WIRING HARNESS REPLACEMENT............................................................................. WP 0660 Figure 1. Figure 2. Figure 3. Figure 4. 400 Hz Supply Wiring Harness Removal............................................................................. 0660-3 400 Hz Wiring Harness Removal......................................................................................... 0660-5 400 Hz Supply Wiring Harness Installation.......................................................................... 0660-7 400 Hz Supply Wiring Harness Removal............................................................................. 0660-9
BRANCHED 400 HZ RECEPTACLE WIRING HARNESS REPLACEMENT.............................................. WP 0661 Figure 1. Figure 2. Branched 400 Hz Receptacle Wiring Harness Removal...................................................... 0661-2 Branched 400 Hz Receptacle Wiring Harness Removal...................................................... 0661-3
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Page No. WP Sequence No. Figure 3. Figure 4. Branched 400 Hz Receptacle Wiring Harness Installation................................................... 0661-4 Branched 400 Hz Receptacle Wiring Harness Installation................................................... 0661-5
TELEPHONE POST WIRING HARNESS REPLACEMENT........................................................................ WP 0662 Figure 1. Figure 2. Telephone Post Wiring Harness Removal........................................................................... 0662-2 Telephone Post Wiring Harness Installation........................................................................ 0662-3
3 PHASE RECEPTACLE WIRING HARNESS REPLACEMENT................................................................ WP 0663 Figure 1. Figure 2. 3 Phase Receptacle Wiring Harness Removal.................................................................... 0663-3 3 Phase Receptacle Wiring Harness Removal.................................................................... 0663-5
FORWARD DECK PLATE REPLACEMENT............................................................................................... WP 0664 Figure 1. Figure 2. Forward Deck Plate Removal............................................................................................... 0664-2 Forward Deck Plate Installation............................................................................................ 0664-3
CRANE BODY HOUSING ASSEMBLY COVER REPLACEMENT............................................................. WP 0665 Figure 1. Figure 2. Crane Body Housing Assembly Cover Removal.................................................................. 0665-2 Crane Body Housing Assembly Cover Installation............................................................... 0665-3
WRECKER BODY REPLACEMENT........................................................................................................... WP 0666 Figure 1. Figure 2. Wrecker Body Removal........................................................................................................ 0666-3 Wrecker Body Installation..................................................................................................... 0666-5
FUEL CAN BRACKET REPLACEMENT..................................................................................................... WP 0667 Figure 1. Figure 2. Fuel Can Bracket Removal.................................................................................................. 0667-3 Fuel Can Bracket Installation............................................................................................... 0667-5
FRONT WINCH REPLACEMENT............................................................................................................... WP 0668 Figure 1. Figure 2. Front Winch Removal........................................................................................................... 0668-3 Front Winch Installation........................................................................................................ 0668-5
REAR WINCH ADJUSTMENT..................................................................................................................... WP 0669 Figure 1. Figure 2. Cable Tensioner Check........................................................................................................ 0669-1 Cable Tensioner Adjustment................................................................................................ 0669-2
REAR WINCH REPLACEMENT.................................................................................................................. WP 0670
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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Rear Winch Removal........................................................................................................... 0670-1 Rear Winch Removal........................................................................................................... 0670-2 Rear Winch Removal........................................................................................................... 0670-3 Rear Winch Removal........................................................................................................... 0670-4 Rear Winch Removal........................................................................................................... 0670-5 Rear Winch Installation........................................................................................................ 0670-6 Rear Winch Installation........................................................................................................ 0670-7 Rear Winch Installation........................................................................................................ 0670-8 Rear Winch Installation........................................................................................................ 0670-9 Rear Winch Installation...................................................................................................... 0670-10
WINCH FRAME EXTENSION REPLACEMENT......................................................................................... WP 0671 Figure 1. Figure 2. Winch Frame Extension Removal........................................................................................ 0671-3 Winch Frame Extension Installation..................................................................................... 0671-5
FRONT WINCH AUTOMATIC BRAKE ADJUSTMENT............................................................................... WP 0672 Figure 1. Figure 2. Front Winch Automatic Brake Testing.................................................................................. 0672-3 Front Winch Automatic Brake Adjustment............................................................................ 0672-4
FRONT WINCH DRAG BRAKE ADJUSTMENT.......................................................................................... WP 0673 Figure 1. Figure 2. Figure 3. Front Winch Drag Brake Testing.......................................................................................... 0673-1 Front Winch Drag Brake Testing.......................................................................................... 0673-2 Front Winch Drag Brake Adjustment.................................................................................... 0673-3
FRONT WINCH CABLE CHAIN AND HOOK REPLACEMENT.................................................................. WP 0674 Figure 1. Figure 2. Front Winch Cable Chain and Hook Removal...................................................................... 0674-1 Front Winch Cable Chain and Hook Installation................................................................... 0674-2
FRONT WINCH CABLE CLEVIS REPLACEMENT..................................................................................... WP 0675 Figure 1. Figure 2. Figure 3. Front Winch Cable Clevis Removal...................................................................................... 0675-2 Front Winch Cable Clevis Removal...................................................................................... 0675-3 Front Winch Cable Clevis Installation................................................................................... 0675-4
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Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Front Winch Cable Clevis Installation................................................................................... 0675-5 Front Winch Cable Clevis Installation................................................................................... 0675-5 Front Winch Cable Clevis Installation................................................................................... 0675-6 Front Winch Cable Clevis Installation................................................................................... 0675-6 Front Winch Cable Clevis Installation................................................................................... 0675-7
REAR WINCH ROLLER REPAIR................................................................................................................ WP 0676 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Rear Winch Roller Repair - Side Roller Disassembly.......................................................... 0676-2 Rear Winch Roller Repair - Top and Bottom Roller Disassembly........................................ 0676-3 Rear Winch Roller Cleaning and Inspection......................................................................... 0676-5 Rear Winch Roller Repair - Top and Bottom Roller Assembly............................................. 0676-6 Rear Winch Roller Repair - Side Roller Assembly............................................................... 0676-7
FRONT WINCH CABLE TENSIONER REPAIR.......................................................................................... WP 0677 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Cable Tensioner Removal.................................................................................................... 0677-2 Cable Tensioner Disassembly.............................................................................................. 0677-3 Cable Tensioner Cleaning and Inspection........................................................................... 0677-5 Cable Tensioner Assembly.................................................................................................. 0677-6 Cable Tensioner Assembly.................................................................................................. 0677-7 Cable Tensioner................................................................................................................... 0677-8
FRONT AND REAR WINCH LEVEL WIND REPAIR................................................................................... WP 0678 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Level Wind Disassembly...................................................................................................... 0678-3 Level Wind Disassembly...................................................................................................... 0678-5 Level Wind Disassembly...................................................................................................... 0678-7 Level Wind Cleaning and Inspection.................................................................................... 0678-9 Level Wind Cleaning and Inspection.................................................................................. 0678-10 Level Wind Assembly......................................................................................................... 0678-11 Level Wind Assembly......................................................................................................... 0678-13 Level Wind Assembly......................................................................................................... 0678-15
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Page No. WP Sequence No. FRONT WINCH ROLLER ASSEMBLY REPAIR......................................................................................... WP 0679 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Front Winch Roller Assembly Removal................................................................................ 0679-2 Roller Assembly Disassembly.............................................................................................. 0679-3 Roller Assembly Cleaning and Inspection............................................................................ 0679-5 Roller Assembly................................................................................................................... 0679-7 Roller Assembly................................................................................................................... 0679-9 Roller Assembly Installation............................................................................................... 0679-10
FRONT WINCH CONTROL VALVE CABLE REPLACEMENT................................................................... WP 0680 Figure 1. Figure 2. Figure 3. Figure 4. Front Winch Control Valve Cable Removal.......................................................................... 0680-2 Winch Control Valve Cable.................................................................................................. 0680-3 Winch Control Valve Cable.................................................................................................. 0680-4 Winch Control Valve Cable Installation................................................................................ 0680-5
FRONT AND REAR WINCH CONTROL VALVE REPLACEMENT............................................................. WP 0681 Figure 1. Figure 2. Front and Rear Winch Control Valve Removal.................................................................... 0681-3 Front and Rear Winch Control Valve Installation................................................................. 0681-5
REAR WINCH HYDRAULIC MOTOR REPLACEMENT.............................................................................. WP 0682 Figure 1. Figure 2. Figure 3. Figure 4. Rear Winch Hydraulic Motor Removal................................................................................. 0682-3 Rear Winch Hydraulic Motor Hoses and Fittings Removal.................................................. 0682-5 Rear Winch Hydraulic Motor Hoses and Fittings Installation............................................... 0682-7 Rear Winch Hydraulic Motor Installation.............................................................................. 0682-9
FRONT WINCH HYDRAULIC PUMP REPLACEMENT.............................................................................. WP 0683 Figure 1. Figure 2. Front Winch Hydraulic Motor Removal................................................................................. 0683-2 Front Winch Hydraulic Motor Installation.............................................................................. 0683-3
FRONT WINCH CABLE REPLACEMENT................................................................................................... WP 0684 Figure 1. Figure 2. Front Winch Cable Removal................................................................................................ 0684-3 Front Winch Cable Installation............................................................................................. 0684-5
FRONT WINCH HYDRAULIC HOSE AND TUBE REPLACEMENT........................................................... WP 0685
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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Hydraulic Oil Reservoir Hoses Removal.............................................................................. 0685-3 Front Winch Hydraulic Hoses and Tubes Removal.............................................................. 0685-5 Hydraulic Oil Reservoir Hoses Removal.............................................................................. 0685-6 Hydraulic Oil Reservoir Hoses Removal.............................................................................. 0685-7 Hydraulic Oil Reservoir Hoses Installation........................................................................... 0685-8 Hydraulic Oil Reservoir Hoses Installation........................................................................... 0685-9 Front Winch Hydraulic Hoses and Tubes Installation......................................................... 0685-11 Hydraulic Tubes and Hoses Installation............................................................................. 0685-13
BOOM REPLACEMENT.............................................................................................................................. WP 0686 Figure 1. Figure 2. Boom Removal..................................................................................................................... 0686-3 Boom Installation.................................................................................................................. 0686-5
INNER BOOM REPLACEMENT.................................................................................................................. WP 0687 Figure 1. Figure 2. Inner Boom Removal............................................................................................................ 0687-3 Inner Boom Installation......................................................................................................... 0687-5
BOOM ROLLER REPAIR............................................................................................................................ WP 0688 Figure 1. Figure 2. Boom Roller Removal.......................................................................................................... 0688-3 Boom Roller Installation....................................................................................................... 0688-5
CRANE SWIVEL VALVE REPAIR............................................................................................................... WP 0689 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Wiring Harness Removal...................................................................................................... 0689-3 Crane Swivel Valve Removal............................................................................................... 0689-5 Crane Swivel Valve Removal............................................................................................... 0689-7 Crane Swivel Valve Installation............................................................................................ 0689-9 Crane Swivel Valve Installation.......................................................................................... 0689-11 Wiring Harness Connections.............................................................................................. 0689-13
CRANE HYDRAULIC SWING MOTOR REPLACEMENT........................................................................... WP 0690 Figure 1. Figure 2. Crane Hydraulic Swing Motor Removal............................................................................... 0690-3 Crane Hydraulic Swing Motor Installation............................................................................ 0690-4
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Page No. WP Sequence No. CRANE SWING GEARCASE REPLACEMENT.......................................................................................... WP 0691 Figure 1. Figure 2. Crane Swing Gearcase Removal......................................................................................... 0691-2 Crane Swing Gearcase Installation...................................................................................... 0691-3
TURNTABLE REPAIR................................................................................................................................. WP 0692 Figure 1. Figure 2. Figure 3. Figure 4. Turntable Removal............................................................................................................... 0692-2 Turntable Gear and Bearing Removal.................................................................................. 0692-3 Turntable Gear and Bearing Installation............................................................................... 0692-5 Turntable Installation............................................................................................................ 0692-7
BOOM ELEVATING CYLINDER REPLACEMENT...................................................................................... WP 0693 Figure 1. Figure 2. Boom Elevating Cylinder Removal....................................................................................... 0693-3 Boom Elevating Cylinder Installation.................................................................................... 0693-5
FRONT WINCH MOTOR REPLACEMENT................................................................................................. WP 0694 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Front Winch Motor Removal................................................................................................. 0694-2 Front Winch Motor Removal................................................................................................. 0694-3 Front Winch Motor Removal................................................................................................. 0694-4 Front Winch Motor Installation.............................................................................................. 0694-5 Front Winch Motor Installation.............................................................................................. 0694-5 Front Winch Motor Installation.............................................................................................. 0694-6
BOOM EXTENSION CYLINDER REPLACEMENT..................................................................................... WP 0695 Figure 1. Figure 2. Boom Extension Cylinder Removal...................................................................................... 0695-3 Boom Extension Cylinder Installation................................................................................... 0695-5
HOIST WINCH REPLACEMENT................................................................................................................. WP 0696 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Hoist Winch Removal........................................................................................................... 0696-3 Hoist Winch Disassembly..................................................................................................... 0696-5 Hoist Winch Disassembly..................................................................................................... 0696-7 Hoist Winch Disassembly..................................................................................................... 0696-9 Hoist Winch Disassembly................................................................................................... 0696-11
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Page No. WP Sequence No. Table 1. Figure 6. Figure 7. Figure 8. Figure 9. Hoist Winch Wear Limits.................................................................................................... 0696-13 Hoist Winch Assembly........................................................................................................ 0696-15 Hoist Winch Assembly........................................................................................................ 0696-17 Hoist Winch Assembly........................................................................................................ 0696-19 Hoist Winch Installation...................................................................................................... 0696-20
HOIST LEVEL WIND REPLACEMENT....................................................................................................... WP 0697 Figure 1. Figure 2. Hoist Level Wind Removal................................................................................................... 0697-2 Hoist Level Wind Installation................................................................................................ 0697-3
CRANE GONDOLA CONTROL VALVE REPAIR........................................................................................ WP 0698 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Control Valve Cover Removal.............................................................................................. 0698-2 Hose Removal...................................................................................................................... 0698-3 Crane Gondola Control Valve Disassembly......................................................................... 0698-4 Crane Gondola Control Valve Disassembly......................................................................... 0698-5 Crane Gondola Control Valve Disassembly......................................................................... 0698-6 Crane Gondola Control Valve Disassembly......................................................................... 0698-7 Crane Control Valve Disassembly........................................................................................ 0698-9 Crane Gondola Control Valve Assembly............................................................................ 0698-11 Crane Gondola Control Valve Assembly............................................................................ 0698-12 Crane Gondola Control Valve Assembly............................................................................ 0698-13 Crane Gondola Control Valve Assembly............................................................................ 0698-14 Crane Gondola Control Valve Installation.......................................................................... 0698-15 Crane Gondola Control Valve Installation.......................................................................... 0698-16 Crane Gondola Control Valve Installation.......................................................................... 0698-17
GONDOLA REPAIR..................................................................................................................................... WP 0699 Figure 1. Figure 2. Figure 3. Gondola Removal................................................................................................................. 0699-3 Gondola Removal................................................................................................................. 0699-4 Gondola Installation.............................................................................................................. 0699-5
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Page No. WP Sequence No. Figure 4. Gondola Installation.............................................................................................................. 0699-6
HYDRAULIC HOIST WINCH MOTOR AND LINES REPLACEMENT......................................................... WP 0700 Figure 1. Figure 2. Hydraulic Hoist Winch Motor and Lines Removal................................................................ 0700-3 Hydraulic Hoist Winch Motor and Lines Installation............................................................. 0700-4
WINCH HYDRAULIC OIL RESERVOIR REPLACEMENT.......................................................................... WP 0701 Figure 1. Figure 2. Figure 3. Figure 4. Winch Hydraulic Oil Reservoir Removal.............................................................................. 0701-3 Winch Hydraulic Oil Reservoir Removal.............................................................................. 0701-4 Winch Hydraulic Oil Reservoir Installation........................................................................... 0701-5 Winch Hydraulic Oil Reservoir Installation........................................................................... 0701-6
TRACTOR WINCH HYDRAULIC OIL RESERVOIR REPLACEMENT (M932/A1/A2)................................ WP 0702 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Tractor Winch Hydraulic Oil Reservoir Removal.................................................................. 0702-3 Tractor Winch Hydraulic Oil Reservoir Removal.................................................................. 0702-5 Tractor Winch Hydraulic Oil Reservoir Removal.................................................................. 0702-7 Tractor Winch Hydraulic Oil Reservoir Installation............................................................... 0702-9 Tractor Winch Hydraulic Oil Reservoir Installation............................................................. 0702-10 Tractor Winch Hydraulic Oil Reservoir Installation............................................................. 0702-11
WRECKER HYDRAULIC OIL RESERVOIR, BRACKETS AND STRAPS REPAIR.................................... WP 0703 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Hydraulic Oil Reservoir Removal......................................................................................... 0703-3 Hydraulic Oil Reservoir Brackets and Straps Removal........................................................ 0703-4 Hydraulic Oil Reservoir Disassembly................................................................................... 0703-5 Hydraulic Oil Reservoir, Brackets and Straps Assembly...................................................... 0703-7 Hydraulic Oil Reservoir Brackets and Straps Installation..................................................... 0703-8 Hydraulic Oil Reservoir Installation...................................................................................... 0703-9
WINCH HYDRAULIC OIL RESERVOIR FILTER REPLACEMENT............................................................. WP 0704 Figure 1. Figure 2. Winch Hydraulic Oil Reservoir Filter Removal..................................................................... 0704-3 Winch Hydraulic Oil Reservoir Filter Installation.................................................................. 0704-5
PRESSURE RELIEF VALVE ADJUSTMENT.............................................................................................. WP 0705
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Page No. WP Sequence No. Figure 1. Figure 2. Pressure Relief Valve Testing.............................................................................................. 0705-2 Pressure Relief Valve Adjustment........................................................................................ 0705-3
SNUBBER VALVE ASSEMBLY REPLACEMENT....................................................................................... WP 0706 Figure 1. Figure 2. Snubber Valve Assembly Removal...................................................................................... 0706-3 Snubber Valve Assembly Installation................................................................................... 0706-5
CRANE HYDRAULIC FILTER AND HOUSING REPAIR............................................................................ WP 0707 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Hydraulic Oil Filter Housing.................................................................................................. 0707-3 Hydraulic Crane Filter........................................................................................................... 0707-4 Hydraulic Crane Filter........................................................................................................... 0707-5 Crane Hydraulic Filter........................................................................................................... 0707-7 Crane Hydraulic Filter........................................................................................................... 0707-8 Hydraulic Oil Filter Housing.................................................................................................. 0707-9
AUTOMATIC BRAKE (HOIST WINCH) SERVICING.................................................................................. WP 0708 Figure 1. Automatic Brake (Hoist Winch) Adjustment......................................................................... 0708-2
HOIST WINCH CABLE REPLACEMENT.................................................................................................... WP 0709 Figure 1. Figure 2. Figure 3. Figure 4. Hoist Winch Cable Removal................................................................................................. 0709-3 Hoist Winch Cable Removal................................................................................................. 0709-4 Hoist Winch Cable Installation.............................................................................................. 0709-5 Hoist Winch Cable Installation.............................................................................................. 0709-7
REAR WINCH CABLE REPLACEMENT..................................................................................................... WP 0710 Figure 1. Figure 2. Figure 3. Figure 4. Rear Winch Cable Removal................................................................................................. 0710-1 Rear Winch Cable Removal................................................................................................. 0710-2 Rear Winch Cable Installation.............................................................................................. 0710-3 Rear Winch Cable Installation.............................................................................................. 0710-3
WRECKER CRANE HYDRAULIC HOSE AND TUBE REPLACEMENT..................................................... WP 0711 Figure 1. Figure 2. Wrecker Crane Hydraulic Hose and Tube Removal............................................................ 0711-3 Wrecker Crane Hydraulic Hose and Tube Installation......................................................... 0711-5
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Page No. WP Sequence No. WRECKER CRANE HYDRAULIC PUMP REPLACEMENT........................................................................ WP 0712 Figure 1. Figure 2. Wrecker Crane Hydraulic Pump Removal............................................................................ 0712-3 Wrecker Crane Hydraulic Pump Installation......................................................................... 0712-5
TRANSMISSION PTO-TO-HYDRAULIC PUMP PROPELLER SHAFT REPAIR........................................ WP 0713 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Transmission PTO-To-Hydraulic Pump Propeller Shaft Removal........................................ 0713-1 Transmission PTO-To-Hydraulic Pump Propeller Shaft Removal........................................ 0713-2 Transmission PTO-To-Hydraulic Pump Propeller Shaft Removal........................................ 0713-3 Transmission PTO-To-Hydraulic Pump Propeller Shaft Removal........................................ 0713-3 Transmission PTO-To-Hydraulic Pump Propeller Shaft Assembly...................................... 0713-4 Transmission PTO-To-Hydraulic Pump Propeller Shaft Assembly...................................... 0713-5 Transmission PTO-To-Hydraulic Pump Propeller Shaft Assembly...................................... 0713-6 Transmission PTO-To-Hydraulic Pump Propeller Shaft Assembly...................................... 0713-7 Transmission PTO-To-Hydraulic Pump Propeller Shaft Installation..................................... 0713-8
TRANSFER PTO-TO-HYDRAULIC PUMP PROPELLER SHAFT REPAIR................................................ WP 0714 Figure 1. Figure 2. Transfer PTO-to-Hydraulic Pump Propeller Shaft Removal................................................. 0714-2 Transfer PTO-to-Hydraulic Pump Propeller Shaft Installation.............................................. 0714-3
DUMP BODY HYDRAULIC HOSE REPLACEMENT.................................................................................. WP 0715 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Hydraulic Hoses................................................................................................................... 0715-3 Hydraulic Hoses................................................................................................................... 0715-4 Hydraulic Hoses................................................................................................................... 0715-5 Hydraulic Hoses................................................................................................................... 0715-6 Hydraulic Hoses................................................................................................................... 0715-7 Hydraulic Hoses................................................................................................................... 0715-8
DUMP VALVE CABLE AND SHIFT LEVER REPLACEMENT.................................................................... WP 0716 Figure 1. Figure 2. Valve Cable and Shift Lever Removal.................................................................................. 0716-3 Valve Cable and Shift Lever Installation............................................................................... 0716-5
DUMP SUBFRAME REPLACEMENT......................................................................................................... WP 0717
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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Dump Subframe Removal.................................................................................................... 0717-3 Dump Subframe Removal.................................................................................................... 0717-5 Dump Subframe Removal.................................................................................................... 0717-7 Dump Subframe Installation................................................................................................. 0717-9 Dump Subframe Installation............................................................................................... 0717-10
DUMP SAFETY BRACE REPLACEMENT.................................................................................................. WP 0718 Figure 1. Figure 2. Dump Safety Brace Removal............................................................................................... 0718-2 Dump Safety Brace Installation............................................................................................ 0718-3
DUMP HYDRAULIC PUMP REPLACEMENT............................................................................................. WP 0719 DUMP CONTROL VALVE REPLACEMENT............................................................................................... WP 0720 FRONT AND REAR WINCH CONTROL VALVE REPLACEMENT (M930/A1/A2)..................................... WP 0721 Figure 1. Figure 2. Figure 3. Figure 4. Front and Rear Winch Control Valve Removal.................................................................... 0721-2 Front and Rear Winch Control Valve Removal.................................................................... 0721-3 Front and Rear Winch Control Valve Installation................................................................. 0721-4 Front and Rear Winch Control Valve Installation................................................................. 0721-5
REAR WINCH CABLE TENSIONER REPAIR............................................................................................. WP 0722 Figure 1. Figure 2. Figure 3. Figure 4. Rear Winch Cable Tensioner Disassembly.......................................................................... 0722-3 Rear Winch Cable Tensioner Disassembly.......................................................................... 0722-5 Rear Winch Cable Tensioner Assembly............................................................................... 0722-7 Rear Winch Assembly.......................................................................................................... 0722-8
DUMP ROLLER ARM REPLACEMENT...................................................................................................... WP 0723 Figure 1. Figure 2. Dump Roller Removal.......................................................................................................... 0723-2 Dump Roller Installation....................................................................................................... 0723-3
DUMP HOIST CYLINDER REPLACEMENT............................................................................................... WP 0724 Figure 1. Figure 2. Figure 3. Dump Hoist Cylinder Removal............................................................................................. 0724-2 Dump Hoist Cylinder Removal............................................................................................. 0724-3 Dump Hoist Cylinder Removal............................................................................................. 0724-4
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Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Dump Hoist Cylinder Installation.......................................................................................... 0724-5 Dump Hoist Cylinder Installation.......................................................................................... 0724-6 Dump Hoist Cylinder Installation.......................................................................................... 0724-7
TRANSFER CASE POWER TAKEOFF (PTO) REPLACEMENT................................................................ WP 0725 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Transfer Case PTO Removal............................................................................................... 0725-3 PTO Shaft Disassembly....................................................................................................... 0725-5 PTO Shift Lever Disassembly.............................................................................................. 0725-6 PTO Clutch Collar Disassembly........................................................................................... 0725-7 PTO Disassembly................................................................................................................. 0725-8 PTO Disassembly................................................................................................................. 0725-9 PTO Disassembly................................................................................................................. 0725-9 PTO Disassembly............................................................................................................... 0725-10 PTO Cleaning and Inspection............................................................................................ 0725-11 PTO Cleaning and Inspection............................................................................................ 0725-11 PTO Cleaning and Inspection............................................................................................ 0725-12 PTO Cleaning and Inspection............................................................................................ 0725-12 Transfer Case PTO Assembly............................................................................................ 0725-13 Transfer Case PTO Assembly............................................................................................ 0725-14 Transfer Case PTO Assembly............................................................................................ 0725-15 Transfer Case PTO Assembly............................................................................................ 0725-17 Transfer Case PTO Assembly............................................................................................ 0725-19 Transfer Case PTO Assembly............................................................................................ 0725-20 Transfer Case PTO Assembly............................................................................................ 0725-21 Transfer Case PTO Assembly............................................................................................ 0725-21 Transfer Case PTO Installation.......................................................................................... 0725-23
TRANSFER CASE POWER TAKEOFF (PTO) CONTROL CABLE REPLACEMENT................................ WP 0726 Figure 1. Transfer Case PTO Control Cable Removal........................................................................ 0726-2
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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Transfer Case PTO Control Cable Removal........................................................................ 0726-3 Transfer Case PTO Control Cable Installation..................................................................... 0726-4 Transfer Case PTO Control Cable Installation..................................................................... 0726-5
TRANSFER CASE POWER TAKEOFF (PTO) CROSS SHAFT (CONTROL LEVER) REPLACEMENT.......................................................................................................................................... WP 0727 Figure 1. Figure 2. Transfer Case PTO Cross Shaft (Control Lever) Removal.................................................. 0727-3 Transfer Case PTO Cross Shaft (Control Lever) Installation............................................... 0727-5
TRANSMISSION POWER TAKEOFF (PTO) REPLACEMENT................................................................... WP 0728 Figure 1. Figure 2. Figure 3. Figure 4. Transmission PTO Removal................................................................................................ 0728-3 Transmission PTO Removal................................................................................................ 0728-5 Transmission PTO Installation............................................................................................. 0728-7 Transmission PTO Installation............................................................................................. 0728-9
TRANSMISSION POWER TAKEOFF (PTO) CONTROL CABLE REPLACEMENT................................... WP 0729 Figure 1. Figure 2. Figure 3. Figure 4. Transmission Control Cable Removal.................................................................................. 0729-2 Transmission Control Cable Removal.................................................................................. 0729-3 Transmission Control Cable Installation............................................................................... 0729-4 Transmission Control Cable Installation............................................................................... 0729-5
TRANSMISSION POWER TAKEOFF (PTO) CONTROL CABLE REPLACEMENT (M939A2)..................................................................................................................................................... WP 0730 Figure 1. Figure 2. Figure 3. Figure 4. Transmission PTO Control Cable Removal (M939A2)......................................................... 0730-2 Transmission PTO Control Cable Removal (M939A2)......................................................... 0730-3 Transmission PTO Control Cable Installation (M939A2)...................................................... 0730-4 Transmission PTO Control Cable Installation (M939A2)...................................................... 0730-5
CARGO BODY COVER BOWS REPLACEMENT....................................................................................... WP 0731 Figure 1. Figure 2. Cargo Body Cover Bows Removal....................................................................................... 0731-2 Cargo Body Cover Bows Installation.................................................................................... 0731-3
CAB TURNBUTTONS AND LASHING HOOKS REPLACEMENT.............................................................. WP 0732 Figure 1. Cab Turnbuttons and Lashing Hooks Removal.................................................................... 0732-2
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Page No. WP Sequence No. Figure 2. Cab Turnbuttons and Lashing Hooks Installation................................................................. 0732-3
CAB TOP SEAL AND RETAINER REPAIR................................................................................................. WP 0733 Figure 1. Figure 2. Cab Top Seal and Retainer Repair...................................................................................... 0733-1 Cab Top Seal and Retainer Installation................................................................................ 0733-2
CARGO LOWER WHEEL SPLASH GUARD REPLACEMENT................................................................... WP 0734 Figure 1. Figure 2. Lower Wheel Splash Guard Replacement........................................................................... 0734-1 Lower Wheel Splash Guard Installation............................................................................... 0734-2
WINDSHIELD WIPER CONTROL VALVE REPLACEMENT...................................................................... WP 0735 Figure 1. Figure 2. Windshield Wiper Control Valve Removal............................................................................ 0735-3 Windshield Wiper Control Valve Installation......................................................................... 0735-4
WINDSHIELD WIPER BLADE, WIPER ARM, AND WIPER MOTOR REPLACEMENT............................. WP 0736 Figure 1. Figure 2. Windshield Wiper Blade, Wiper Arm, and Wiper Motor Removal........................................ 0736-3 Windshield Wiper Blade, Wiper Arm, and Wiper Motor Removal........................................ 0736-4
WINDSHIELD WIPER RESERVOIR, JET, CONTROL, AND WASHER HOSES REPLACEMENT.......................................................................................................................................... WP 0737 Figure 1. Figure 2. Figure 3. Figure 4. Windshield Washer Hoses Removal.................................................................................... 0737-2 Windshield Washer Hoses Installation................................................................................. 0737-3 Windshield Wiper Reservoir Removal.................................................................................. 0737-5 Windshield Wiper Reservoir Installation............................................................................... 0737-7
REARVIEW MIRROR AND BRACE REPLACEMENT................................................................................ WP 0738 Figure 1. Figure 2. Rearview Mirror and Brace Removal................................................................................... 0738-3 Rearview Mirror and Brace Installation................................................................................ 0738-5
WASHER CONTROL VALVE REPLACEMENT.......................................................................................... WP 0739 Figure 1. Figure 2. Washer Control Valve Removal........................................................................................... 0739-3 Washer Control Valve Installation........................................................................................ 0739-4
REFLECTORS REPLACEMENT................................................................................................................. WP 0740 Figure 1. Figure 2. Reflectors Removal.............................................................................................................. 0740-1 Reflectors Installation........................................................................................................... 0740-2
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Page No. WP Sequence No. FRESH AIR VENT CONTROL CABLE ASSEMBLY REPLACEMENT....................................................... WP 0741 Figure 1. Figure 2. Figure 3. Figure 4. Fresh Air Vent Control Assembly Removal.......................................................................... 0741-1 Fresh Air Vent Control Assembly Removal.......................................................................... 0741-2 Fresh Air Vent Control Assembly Installation....................................................................... 0741-3 Fresh Air Vent Control Assembly Installation....................................................................... 0741-4
DIVERTER ASSEMBLY REPLACEMENT.................................................................................................. WP 0742 Figure 1. Figure 2. Figure 3. Figure 4. Diverter Assembly Removal................................................................................................. 0742-1 Diverter Assembly Removal................................................................................................. 0742-2 Diverter Assembly Installation.............................................................................................. 0742-3 Diverter Assembly Installation.............................................................................................. 0742-4
FRESH AIR INLET DUCTING REPLACEMENT......................................................................................... WP 0743 Figure 1. Figure 2. Fresh Air Inlet Ducting Removal........................................................................................... 0743-2 Fresh Air Inlet Ducting Installation........................................................................................ 0743-3
CAB HEAT AND DEFROST AIR DUCTING REPLACEMENT.................................................................... WP 0744 Figure 1. Figure 2. Cab Heat and Defrost Air Ducting Removal......................................................................... 0744-1 Cab Heat and Defrost Air Ducting Installation...................................................................... 0744-2
DEFROST AND HEAT CONTROLS REPLACEMENT................................................................................ WP 0745 Figure 1. Figure 2. Figure 3. Figure 4. Defrost and Heat Controls Removal..................................................................................... 0745-2 Defrost and Heat Controls Removal..................................................................................... 0745-3 Defrost and Heat Controls Installation.................................................................................. 0745-4 Defrost and Heat Controls Installation.................................................................................. 0745-5
PERSONNEL HEATER HOSES REPLACEMENT...................................................................................... WP 0746 Figure 1. Figure 2. Personnel Heater Hoses Removal....................................................................................... 0746-3 Personnel Heater Hoses Installation.................................................................................... 0746-4
PERSONNEL HOT WATER HEATER REPLACEMENT............................................................................. WP 0747 Figure 1. Figure 2. Personnel Hot Water Heater Removal................................................................................. 0747-3 Personnel Hot Water Heater Installation.............................................................................. 0747-5
xxxiii
TM 9-2320-272-23-4

Page No. WP Sequence No. ENGINE COOLANT HEATER REPLACEMENT......................................................................................... WP 0748 Figure 1. Figure 2. Engine Coolant Heater Removal.......................................................................................... 0748-3 Engine Coolant Heater Installation....................................................................................... 0748-5
RADIATOR COVER KIT REPLACEMENT.................................................................................................. WP 0749 Figure 1. Figure 2. Radiator Cover Kit Removal................................................................................................. 0749-1 Radiator Cover Kit Installation.............................................................................................. 0749-2
HARDTOP KIT REPLACEMENT................................................................................................................. WP 0750 Figure 1. Figure 2. Hardtop Kit Removal............................................................................................................ 0750-3 Hardtop Kit Installation......................................................................................................... 0750-5
PERSONNEL FUEL BURNING HEATER AND MOUNTING BRACKET REPLACEMENT (M939/ A1)............................................................................................................................................................... WP 0751 Figure 1. Figure 2. Personnel Fuel Burning Heater and Mounting Bracket Removal (M939/A1)....................... 0751-2 Personnel Fuel Burning Heater and Mounting Bracket Installation (M939/A1).................... 0751-3
ENGINE COOLANT HEATER PUMP REPLACEMENT.............................................................................. WP 0752 Figure 1. Figure 2. Engine Coolant Heater Pump Removal............................................................................... 0752-3 Engine Coolant Heater Pump Installation............................................................................ 0752-5
ENGINE COOLANT HEATER CONTROL BOX REPLACEMENT.............................................................. WP 0753 Figure 1. Figure 2. Engine Coolant Heater Control Box Removal...................................................................... 0753-2 Engine Coolant Heater Control Box Installation................................................................... 0753-3
ENGINE COOLANT HEATER HARNESS REPLACEMENT (M939/A1)..................................................... WP 0754 Figure 1. Figure 2. Engine Coolant Heater Harness Removal........................................................................... 0754-3 Engine Coolant Heater Harness Installation........................................................................ 0754-5
ENGINE COOLANT HEATER HARNESS REPLACEMENT (M939/A2)..................................................... WP 0755 Figure 1. Figure 2. Engine Coolant Heater Harness Removal........................................................................... 0755-3 Engine Coolant Heater Harness Installation........................................................................ 0755-5
ENGINE COOLANT OIL PAN SHROUD AND EXHAUST TUBE REPLACEMENT.................................... WP 0756 Figure 1. Figure 2. Engine Coolant Oil Pan Shroud and Exhaust Tube Removal.............................................. 0756-2 Engine Coolant Oil Pan Shroud and Exhaust Tube Installation........................................... 0756-3
xxxiv
TM 9-2320-272-23-4

Page No. WP Sequence No. ENGINE COOLANT HEATER HOSE REPLACEMENT.............................................................................. WP 0757 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Engine Coolant Heater Hose Removal................................................................................ 0757-3 Engine Coolant Heater Hose Removal................................................................................ 0757-5 Engine Coolant Heater Hose Removal................................................................................ 0757-6 Engine Coolant Heater Hose Installation............................................................................. 0757-7 Hoses and Electrical Harness Installation............................................................................ 0757-9 Engine Coolant Heater Hose Installation........................................................................... 0757-11
ENGINE COOLANT BATTERY BOX HEATER PAD REPLACEMENT....................................................... WP 0758 Figure 1. Figure 2. Engine Coolant Battery Box Heater Pad Removal............................................................... 0758-3 Engine Coolant Battery Box Heater Pad Installation............................................................ 0758-5
PERSONNEL FUEL BURNING HEATER CONTROL BOX REPLACEMENT............................................ WP 0759 Figure 1. Figure 2. Personnel Fuel Burning Heater Control Box Removal......................................................... 0759-2 Personnel Fuel Burning Heater Control Box Installation...................................................... 0759-3
PERSONNEL FUEL BURNING HEATER AND MOUNTING BRACKETS REPLACEMENT (M939A2)..................................................................................................................................................... WP 0760 Figure 1. Figure 2. Personnel Fuel Burning Heater and Mounting Brackets Removal....................................... 0760-3 Personnel Fuel Burning Heater and Mounting Brackets Installation.................................... 0760-4
PERSONNEL FUEL BURNING HEATER FUEL PUMP REPLACEMENT (M939/A1)................................ WP 0761 Figure 1. Figure 2. Personnel Fuel Burning Heater Fuel Pump Removal.......................................................... 0761-3 Personnel Fuel Burning Heater Fuel Pump Installation....................................................... 0761-5
PERSONNEL FUEL BURNING HEATER ELECTRIC FUEL PUMP REPLACEMENT (M939A2)..................................................................................................................................................... WP 0762 Figure 1. Figure 2. Personnel Fuel Burning Heater Electric Fuel Pump Removal.............................................. 0762-3 Personnel Fuel Burning Heater Electric Fuel Pump Installation........................................... 0762-4
PERSONNEL FUEL BURNING HEATER FUEL SHUTOFF VALVE REPLACEMENT............................... WP 0763 Figure 1. Figure 2. Fuel Burning Heater Fuel Shutoff Valve Removal................................................................ 0763-3 Fuel Burning Heater Fuel Shutoff Valve Installation............................................................. 0763-5
PERSONNEL FUEL BURNING HEATER WIRING HARNESS REPLACEMENT....................................... WP 0764
xxxv
TM 9-2320-272-23-4

Page No. WP Sequence No. Figure 1. Figure 2. Personnel Fuel Burning Heater Wiring Harness Removal................................................... 0764-3 Personnel Fuel Burning Heater Wiring Harness Installation................................................ 0764-5
PERSONNEL FUEL BURNING HEATER EXHAUST TUBE REPLACEMENT (M939/A1)......................... WP 0765 Figure 1. Figure 2. Fuel Burning Heater Exhaust Tube Removal....................................................................... 0765-3 Fuel Burning Heater Exhaust Tube Installation.................................................................... 0765-5
PERSONNEL FUEL BURNING HEATER EXHAUST TUBE REPLACEMENT (M939A2).......................... WP 0766 Figure 1. Figure 2. Fuel Burning Heater Exhaust Tube Removal....................................................................... 0766-3 Fuel Burning Heater Exhaust Tube Installation.................................................................... 0766-4
PERSONNEL FUEL BURNING HEATER CIRCUIT BREAKER REPLACEMENT...................................... WP 0767 Figure 1. Figure 2. Personnel Fuel Burning Heater Circuit Breaker Removal.................................................... 0767-2 Personnel Fuel Burning Heater Circuit Breaker Installation................................................. 0767-3
DEEPWATER FORDING CONTROL CABLE REPLACEMENT................................................................. WP 0768 Figure 1. Figure 2. Deepwater Fording Control Removal................................................................................... 0768-3 Deepwater Fording Control Installation................................................................................ 0768-5
DEEPWATER FORDING PRESSURIZATION VALVE REPLACEMENT................................................... WP 0769 Figure 1. Figure 2. Figure 3. Figure 4. Deepwater Fording Pressurization Valve Removal (M939/A1)............................................ 0769-3 Deepwater Fording Pressurization Valve Removal (M939/A2)............................................ 0769-5 Deepwater Fording Pressurization Valve Installation (M939/A2)......................................... 0769-7 Deepwater Fording Pressurization Valve Installation (M939/A1)......................................... 0769-9
DEEPWATER FORDING AIR PRESSURE HOSE REPLACEMENT.......................................................... WP 0770 Figure 1. Figure 2. Figure 3. Figure 4. Index Deepwater Fording Air Pressure Hose Removal (M939/A1)................................................ 0770-3 Deepwater Fording Air Pressure Hose Removal (M939A2)................................................. 0770-5 Deepwater Fording Air Pressure Hose Installation (M939A2).............................................. 0770-7 Deepwater Fording Air Pressure Hose Installation (M939/A1)............................................. 0770-9
xxxvi
TM 9-2320-272-23-4
HOW TO USE THIS MANUAL
WARNINGS, CAUTIONS, AND NOTES Read all WARNINGS, CAUTIONS, and NOTES before performing any procedure. Warnings, cautions, notes, subject headings, and other essential information is printed in BOLD type, making them easier for the user to see. GENERAL INFORMATION This manual is divided into CHAPTERS and WORK PACKAGES. For a specific Chapter or Work Package, refer to the TABLE OF CONTENTS. VOLUME 4 The TABLE OF CONTENTS lists the titles of each Chapter and Work Package. CHAPTER 9 provides maintenance instructions. The illustrations throughout this manual contain numerical callouts pointing to various components mentioned in the procedural steps. Mandatory replacement parts must be discarded after removal and replaced with a new part, which is listed in the Materials/Parts section located at the beginning of the task. Prior to performing any maintenance functions on the 5-ton, 6x6, M939, M939A1, and M939A2 Diesel Truck series, ALWAYS do the following: Read and follow all WARNINGS in all work packages. Read the Safety Summary. Read the Equipment Description and Data located in Chapter 1. Read completely through the maintenance procedure to familiarize yourself with the procedure and the affected parts before beginning work. Troubleshooting section is setup by either how a physical problem is occurring or how an active or stored trouble code is read from a diagnostic tool. By following a prescribed flow path through making decisions will lead you to a solution to remedy the problem. RPSTL manual, TM 9-2320-272-24P, is to be used in conjunction with this manual to help find needed parts for procurement. RPSTL manual lists and authorized spares and repair parts; special tools, special Test, Measurement, and Diagnostic Equipment (TMDE); and other special support equipment required for performance of Field Maintenance on the 5-ton, 6x6, M939, M939A1, and M939A2 Diesel Truck series. It authorizes the requisitioning, issue, and disposition of spares, repair parts, and special tools as indicated by the Source, Maintenance, and Recoverability (SMR) codes. METRIC SYSTEM The equipment described herein contains metric components and requires metric, common, and special tools. Therefore, metric units and English units will be used throughout this publication. An English-to-Metric conversion table is included as the last page of this manual inside the back cover.
xxxvii/xxxviii blank
03/15/2011 Rel(1.8) root(howtouse) wpno(F40011)
TM 9-2320-272-23-4
CHAPTER 9 MAINTENANCE INSTRUCTIONS
TM 9-2320-272-23-4
0554
FIELD MAINTENANCE WINDOW BLACKOUT PANEL REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Van body fully expanded and secured (side door window only). (TM 9-2320-272-10)
0554-1
03/15/2011 Rel(1.8) root(maintwp) wpno(M00457)
TM 9-2320-272-23-4
0554
REMOVAL Remove 15 screws (Figure 1, Item 4), guide frame (Figure 1, Item 3), and blackout panel (Figure 1, Item 2) from van body side panel (Figure 1, Item 1).
4
M5315DAA
Figure 1. END OF TASK
Window Blackout Panel Removal.
0554-2
TM 9-2320-272-23-4
0554
INSTALLATION Position blackout panel (Figure 1, Item 2) in guide frame (Figure 1, Item 3), and install on van body side panel (Figure 1, Item 1) with 15 screws (Figure 1, Item 4).
4
M5314DAA
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE
Window Blackout Panel Installation.
Retract and secure van body (side door window only). (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0554-3/4 blank
TM 9-2320-272-23-4
0555
FIELD MAINTENANCE CAB DOOR CHECK ROD REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin Materials/Parts (cont.) (Volume 5, WP 0827, Table 1, Item 329) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0555-1
TM 9-2320-272-23-4
0555
REMOVAL 1. 2. Remove cotter pin (Figure 1, Item 2) from check rod (Figure 1, Item 1) and cab door (Figure 1, Item 3). Discard cotter pin. Open vent door (Figure 1, Item 4) and remove check rod (Figure 1, Item 1) and pad (Figure 1, Item 5).
5 1
M5219DAA
Figure 1. Cab Door Check Rod Removal. END OF TASK
0555-2
TM 9-2320-272-23-4
0555
INSTALLATION 1. 2. Install check rod (Figure 2, Item 1) and pad (Figure 2, Item 5) on vent door (Figure 2, Item 4). Install check rod (Figure 2, Item 1) on cab door (Figure 2, Item 3) with cotter pin (Figure 2, Item 2).
5 1
M5220DAA
Figure 2. END OF TASK END OF WORK PACKAGE
Cab Door Check Rod Installation.
0555-3/4 blank
TM 9-2320-272-23-4
0556
FIELD MAINTENANCE CAB DOOR HINGE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Cab door removed. (Volume 3, WP 0545)
0556-1
TM 9-2320-272-23-4
0556
REMOVAL
NOTE
Upper and lower hinges are replaced the same way. Upper hinge shown. Remove eight screws (Figure 1, Item 4) and hinges (Figure 1, Items 1 and 2) from cab door (Figure 1, Item 3) and cab body (Figure 1, Item 5).
4
M5223DAA
Figure 1. Cab Door Hinge Removal. END OF TASK
0556-2
TM 9-2320-272-23-4
0556
INSTALLATION Install hinges (Figure 2, Items 1 and 2) on cab body (Figure 2, Item 5) and cab door (Figure 2, Item 3) with eight screws (Figure 2, Item 4).
4
M10270DAA
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE Install cab door. (Volume 3, WP 0545) END OF TASK END OF WORK PACKAGE
Cab Door Hinge Installation.
0556-3/4 blank
TM 9-2320-272-23-4
0557
FIELD MAINTENANCE CAB DOOR CATCH REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Screw Assembled Lockwasher Materials/Parts (cont.) (Volume 5, WP 0827, Table 1, Item 84) Qty: 2 Equipment Condition Parking brake set. (TM 9-2320-272-10)
REMOVAL Remove two screw assembled lockwashers (Figure 1, Item 3) and cab door catch (Figure 1, Item 2) from cab body (Figure 1, Item 1).
1 2
M5225DAA
Cab Door Catch Removal.
0557-1
TM 9-2320-272-23-4
0557
INSTALLATION Install cab door catch (Figure 2, Item 2) on cab body (Figure 2, Item 1) with two screw assembled lockwashers (Figure 2, Item 3).
1 2
M5226DAA
Cab Door Catch Installation.
Check cab door for proper operation. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0557-2
TM 9-2320-272-23-4
0558
FIELD MAINTENANCE HOOD LATCH AND BRACKET REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 314) Qty: 4 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10)
0558-1
TM 9-2320-272-23-4
0558
REMOVAL 1. Release hood latch (Figure 1, Item 4).
NOTE
Assistant will help with Step (2). 2. 3. Remove three screws (Figure 1, Item 7), locknuts (Figure 1, Item 6), and hood latch (Figure 1, Item 4) from hood cowl (Figure 1, Item 5). Discard locknuts. Remove three screws (Figure 1, Item 1) and upper latch retaining bracket (Figure 1, Item 2) from hood (Figure 1, Item 3).
0558-2
TM 9-2320-272-23-4
0558
REMOVAL - Continued
2 1 3
4 5 7 6
M5105DAA
Hood Latch & Bracket Removal.
0558-3
TM 9-2320-272-23-4
0558
INSTALLATION 1. Install upper latch retaining bracket (Figure 2, Item 2) on hood (Figure 2, Item 3) with three screws (Figure 2, Item 1).
NOTE
Assistant will help with Step (2). 2. 3. Install hood latch (Figure 2, Item 4) on cab cowl (Figure 2, Item 5) with three screws (Figure 2, Item 7) and locknuts (Figure 2, Item 6). Secure hood latch (Figure 2, Item 4).
0558-4
TM 9-2320-272-23-4
0558
INSTALLATION - Continued
2 1 3
4 5 7 6
M5106DAA
Hood Latch & Bracket Installation.
0558-5/6 blank
TM 9-2320-272-23-4
0559
FIELD MAINTENANCE HOOD SUPPORT BAR BRACKET, CROSSMEMBER, HINGES, AND TORSION BARS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Grease, Automotive and Artillery (Volume 5, WP 0825, Table 1, Item 28) Rag, Wiping (Volume 5, WP 0825, Table 1, Item 53) Cotter Pin (Volume 5, WP 0827, Table 1, Item 254) Qty: 3 Cotter Pin (Volume 5, WP 0827, Table 1, Item 330) Qty: 1 Insulator (Volume 5, WP 0827, Table 1, Item 46) Locknut (Volume 5, WP 0827, Table 1, Item 282) Qty: 3 Locknut (Volume 5, WP 0827, Table 1, Item 285) Qty: 4 Materials/Parts (cont.) Locknut (Volume 5, WP 0827, Table 1, Item 289) Qty: 1 Lockwasher (Volume 5, WP 0827, Table 1, Item 405) Qty: 2 Screw Assembled Lockwasher (Volume 5, WP 0827, Table 1, Item 171) Qty: 6 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10)
0559-1
TM 9-2320-272-23-4
0559
HOOD SUPPORT BAR AND BRACKET REMOVAL
WARNING
Hood must be supported during replacement of hood support bar mounting bracket. Failure to comply may result in injury or death to personnel. 1. 2. 3. 4. 5. Remove bar support pin (Figure 1, Item 10) from stowage bracket (Figure 1, Item 5). Remove cotter pin (Figure 1, Item 14), washer (Figure 1, Item 13), pin (Figure 1, Item 7), and hood support bar (Figure 1, Item 11) from mounting bracket (Figure 1, Item 12). Discard cotter pin. Remove locknut (Figure 1, Item 2), washer (Figure 1, Item 3), and spacer (Figure 1, Item 4) from screw (Figure 1, Item 6). Discard locknut. Remove screw (Figure 1, Item 6), washer (Figure 1, Item 15), and mounting bracket (Figure 1, Item 12) from hood (Figure 1, Item 1). Remove loop link (Figure 1, Item 9) and bar support pin (Figure 1, Item 10) from chain (Figure 1, Item 8).
0559-2
TM 9-2320-272-23-4
0559
HOOD SUPPORT BAR AND BRACKET REMOVAL - Continued
2 1
3 4
6 7 15 14 13 12 11 8 9 10
M5107DAA
Hood Support Bar and Bracket Removal.
0559-3
TM 9-2320-272-23-4
0559
HOOD SUPPORT BAR AND BRACKET INSTALLATION 1. 2. 3. 4. Install loop link (Figure 2, Item 9) and bar support pin (Figure 2, Item 10) on chain (Figure 2, Item 8). Install mounting bracket (Figure 2, Item 12) on hood (Figure 2, Item 1) with screw (Figure 2, Item 6), washer (Figure 2, Item 15), spacer (Figure 2, Item 4), washer (Figure 2, Item 3), and locknut (Figure 2, Item 2). Install hood support bar (Figure 2, Item 11) on mounting bracket (Figure 2, Item 12) with pin (Figure 2, Item 7), washer (Figure 2, Item 13), and cotter pin (Figure 2, Item 14). Install bar support pin (Figure 2, Item 10) on stowage bracket (Figure 2, Item 5).
2 1
3 4
6 7 15 14 13 12 11 8 9 10
M5108DAA
Figure 2. Hood Support Bar and Bracket Installation. END OF TASK
0559-4
TM 9-2320-272-23-4
0559
HOOD RETAINING BRACKET REPLACEMENT 1. 2. Remove two locknuts (Figure 3, Item 4), screws (Figure 3, Item 1), and retaining bracket (Figure 3, Item 2) from front bumper (Figure 3, Item 3). Discard locknuts. Install retaining bracket (Figure 3, Item 2) on front bumper (Figure 3, Item 3) with two screws (Figure 3, Item 1) and locknuts (Figure 3, Item 4).
1 2
4 3 2 3 4
M5109DAA
Hood Retaining Bracket Replacement.
0559-5
TM 9-2320-272-23-4
0559
HOOD CROSSMEMBER BRACKET REMOVAL 1. 2. 3. Remove hood (WP 0565). Remove two screws (Figure 4, Item 9), lockwashers (Figure 4, Item 1), and trunnion bracket (Figure 4, Item 2) from hood crossmember (Figure 4, Item 3). Discard lockwashers. Remove locknut (Figure 4, Item 4), washer (Figure 4, Item 5), through bolt (Figure 4, Item 7), lower trunnion bracket (Figure 4, Item 6), and insulator (Figure 4, Item 8) from trunnion bracket (Figure 4, Item 2). Use softfaced hammer to remove through bolt (Figure 4, Item 7) if necessary. Discard locknut and insulator.
2 1 3 9 8 5 4
6 7
Figure 4. Hood Crossmember Bracket Removal. END OF TASK
M5109-1DAA
0559-6
TM 9-2320-272-23-4
0559
HOOD CROSSMEMBER BRACKET CLEANING AND INSPECTION 1. 2. Wipe trunnion bushings (Figure 5, Item 10) of trunnion brackets (Figure 5, Items 2 and 6) with clean rag. Inspect trunnion bushings (Figure 5, Item 10) for cracks, breaks, and chips. If cracked, broken, or chipped, replace bushings (Figure 5, Item 10).
NOTE
Perform Steps (3) and (4) if trunnion bushings are damaged. 3. 4. Using steel drift and hammer, drive trunnion bushings (Figure 5, Item 10) from trunnion bracket (Figure 5, Item 6). Discard bushings. Using steel drift and hammer, install trunnion bushings (Figure 5, Item 10) in trunnion bracket (Figure 5, Item 6).
2
M5110DAA
Figure 5. Hood Crossmember Bracket Cleaning and Inspection. END OF TASK
0559-7
TM 9-2320-272-23-4
0559
HOOD CROSSMEMBER BRACKET INSTALLATION 1. Install insulator (Figure 6, Item 8) and lower trunnion bracket (Figure 6, Item 6) on trunnion bracket (Figure 6, Item 2) with through bolt (Figure 6, Item 7), washer (Figure 6, Item 5), and locknut (Figure 6, Item 4). Tighten locknut to 96 lb-ft (130 Nm). Install trunnion bracket (Figure 6, Item 2) on hood crossmember (Figure 6, Item 3) with two lockwashers (Figure 6, Item 1) and screws (Figure 6, Item 9). Install hood (WP 0565).
2. 3.
0559-8
TM 9-2320-272-23-4
0559
HOOD CROSSMEMBER BRACKET INSTALLATION - Continued
2 1 3 9 8 5 4
6 7
Figure 6. Hood Crossmember Bracket Installation. END OF TASK
M5111DAA
0559-9
TM 9-2320-272-23-4
0559
HOOD HINGE REMOVAL
NOTE
Left and right hood hinges are replaced the same. This procedure is for the left hood hinge. 1. 2. Remove hood (WP 0565). Remove cotter pin (Figure 7, Item 7) from hinge pin (Figure 7, Item 3). Discard cotter pin.
NOTE
Ensure hood is supported when hinge pins are removed. 3. 4. 5. Remove hinge pin (Figure 7, Item 3) from lower hinge (Figure 7, Item 6) and hood (Figure 7, Item 8). Remove three screw assembled lockwashers (Figure 7, Item 2) and upper hinge half (Figure 7, Item 1) from hood (Figure 7, Item 8). Discard screw assembled lockwashers. Remove three screw assembled lockwashers (Figure 7, Item 4) and lower hinge half (Figure 7, Item 6) from crossmember (Figure 7, Item 5). Discard screw assembled lockwashers.
0559-10
TM 9-2320-272-23-4
0559
HOOD HINGE REMOVAL - Continued
3 1
4 6
5
M5111-1DAA
Hood Hinge Removal.
0559-11
TM 9-2320-272-23-4
0559
HOOD HINGE INSTALLATION
NOTE
Coat hinges and hinge pins with GAA grease. 1. 2. 3. 4. Install lower hinge half (Figure 8, Item 6) on crossmember (Figure 8, Item 5) with three screw assembled lockwashers (Figure 8, Item 4). Install upper hinge half (Figure 8, Item 1) on hood (Figure 8, Item 8) with three screw assembled lockwashers (Figure 8, Item 2). Install hood (Figure 8, Item 8) on lower hinge half (Figure 8, Item 6) with hinge pin (Figure 8, Item 3) and cotter pin (Figure 8, Item 7). Install hood (WP 0565).
0559-12
TM 9-2320-272-23-4
0559
HOOD HINGE INSTALLATION - Continued
3 1
4 6
M5111-2DAA
Hood Hinge Installation. 0559-13
TM 9-2320-272-23-4
0559
TORSION BARS AND CROSSMEMBERS REMOVAL 1. 2. 3. Remove hood (WP 0565). Remove two cotter pins (Figure 9, Item 3) from two hinge pins (Figure 9, Item 5). Discard cotter pins. Remove four locknuts (Figure 9, Item 7) and screws (Figure 9, Item 2) from two torsion bars (Figure 9, Item 1) and mounting brackets (Figure 9, Items 8 and 10). Discard locknuts.
NOTE
Ensure hood and crossmember are supported when hinge pins are removed. 4. 5. Remove two hinge pins (Figure 9, Item 5) and bracket (Figure 9, Item 9) from hood (Figure 9, Item 4). Remove two torsion bars (Figure 9, Item 1) from mounting brackets (Figure 9, Items 8 and 10).
0559-14
TM 9-2320-272-23-4
0559
TORSION BARS AND CROSSMEMBERS REMOVAL - Continued
3 2 4 1
8 7 6 5
10 9
M5112DAA
Torsion Bars and Crossmembers Removal. 0559-15

TM 9-2320-272-23-4
0559
TORSION BARS AND CROSSMEMBERS INSTALLATION
NOTE
Coat hinges and hinge pins with GAA grease. 1. 2. 3. 4. Position two torsion bars (Figure 10, Item 1) in mounting brackets (Figure 10, Items 8 and 10). Install two torsion bars (Figure 10, Item 1) on mounting brackets (Figure 10, Items 8 and 10) with four screws (Figure 10, Item 2) and locknuts (Figure 10, Item 7). Position hood (Figure 10, Item 4) with bracket (Figure 10, Item 9) and hinge (Figure 10, Item 6) and install hinge pin (Figure 10, Item 5) and cotter pin (Figure 10, Item 3). Install hood (WP 0565).
0559-16
TM 9-2320-272-23-4
0559
TORSION BARS AND CROSSMEMBERS INSTALLATION - Continued
3 2 4 1
8 7 6 5
10 9
M5113DAA
Torsion Bars and Crossmembers Installation. 0559-17

TM 9-2320-272-23-4
0559
FOLLOW-ON MAINTENANCE 1. 2. 3. Check bracket placement with hood retaining latch. Lubricate through bolt. (Volume 5, WP 0820) Install hood. (WP 0565)
END OF TASK END OF WORK PACKAGE
0559-18
TM 9-2320-272-23-4
0560
FIELD MAINTENANCE HOOD STOP CABLES REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 285) Qty: 2 Equipment Condition Parking brake off. (TM 9-2320-272-10) Hood raised and secured. (TM 9-2320-272-10)
0560-1
TM 9-2320-272-23-4
0560
REMOVAL
NOTE
Both hood stop cables are replaced the same way. This procedure covers one cable. 1. 2. Remove locknut (Figure 1, Item 7), screw (Figure 1, Item 4), washer (Figure 1, Item 5), and hood stop cable (Figure 1, Item 3) from radiator support bracket (Figure 1, Item 6). Discard locknut. Remove locknut (Figure 1, Item 2), screw (Figure 1, Item 8), washer (Figure 1, Item 9), and hood stop cable (Figure 1, Item 3) from hood bracket (Figure 1, Item 1). Discard locknut.
1 2
9 8
7 6 5 4
M5114DAA
Figure 1. Hood Stop Cables Removal. END OF TASK
0560-2
TM 9-2320-272-23-4
0560
INSTALLATION 1. 2. Install hood stop cable (Figure 2, Item 3) on radiator support bracket (Figure 2, Item 6) with washer (Figure 2, Item 5), screw (Figure 2, Item 4), and locknut (Figure 2, Item 7). Install hood stop cable (Figure 2, Item 3) on hood bracket (Figure 2, Item 1) with washer (Figure 2, Item 9), screw (Figure 2, Item 8), and locknut (Figure 2, Item 2).
9 8
7 6 5 4
M5115DAA
Hood Stop Cables Installation.
0560-3/4 blank
TM 9-2320-272-23-4
0561
FIELD MAINTENANCE HOOD GRAB HANDLE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 282) Qty: 4 Equipment Condition Parking brake set. (TM 9-2320-272-10) Hood raised and secured. (TM 9-2320-272-10)
REMOVAL Remove four screws (Figure 1, Item 5), locknuts (Figure 1, Item 3), two plates (Figure 1, Item 2), and hood grab handle (Figure 1, Item 1) from hood (Figure 1, Item 4). Discard locknuts.
1 2
3 5
4
Figure 1. END OF TASK Hood Grab Handle Removal.
M5116DAA
0561-1
TM 9-2320-272-23-4
0561
INSTALLATION Install hood grab handle (Figure 2, Item 1) on hood (Figure 2, Item 4) with four screws (Figure 2, Item 5), two plates (Figure 2, Item 2), and four locknuts (Figure 2, Item 3).
1 2
3 5
4
Figure 2. END OF TASK END OF WORK PACKAGE Hood Grab Handle Installation.
M9855DAA
0561-2
TM 9-2320-272-23-4
0562
FIELD MAINTENANCE RADIATOR BAFFLES, SEALS, AND PLATES REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 314) Qty: 12 Lockwasher (Volume 5, WP 0827, Table 1, Item 403) Qty: 12 Equipment Condition Parking brake set. (TM 9-2320-272-10) Hood raised and secured. (TM 9-2320-272-10)
0562-1
TM 9-2320-272-23-4
0562
REMOVAL
NOTE
Upper baffle consists of a seal and plate as one unit. Side baffles consist of seals and plates as separate units. 1. 2. Remove four screws (Figure 1, Item 10) and lockwashers (Figure 1, Item 9) from upper radiator baffle seal and plate (Figure 1, Item 1) and brush guard (Figure 1, Item 11). Discard lockwashers. Remove two screws (Figure 1, Item 13), lockwashers (Figure 1, Item 12), and upper radiator baffle seal and plate (Figure 1, Item 1) from left and right baffle plates (Figure 1, Item 5). Discard lockwashers.
NOTE
Steps (3) and (4) apply to both left and right baffle seals and plates. 3. 4. Remove six locknuts (Figure 1, Item 3), washers (Figure 1, Item 4), screws (Figure 1, Item 6), and baffle seal (Figure 1, Item 2) from radiator baffle plate (Figure 1, Item 5). Discard locknuts. Remove three screws (Figure 1, Item 7), lockwashers (Figure 1, Item 8), and baffle plate (Figure 1, Item 5) from brush guard (Figure 1, Item 11). Discard lockwashers.
13 12 1 2 3 4 5 6 7
11
8 5
10
9
M5117DAA
Figure 1. Radiator Baffles, Seals, and Plates Removal. END OF TASK
0562-2
TM 9-2320-272-23-4
0562
INSTALLATION
NOTE
Steps (1) and (2) apply to both left and right baffle seals and plates. 1. 2. 3. 4. Install radiator baffle plate (Figure 2, Item 5) on brush guard (Figure 2, Item 11) with three lockwashers (Figure 2, Item 8) and screws (Figure 2, Item 7). Install baffle seal (Figure 2, Item 2) on baffle plate (Figure 2, Item 5) with six screws (Figure 2, Item 6), washers (Figure 2, Item 4), and locknuts (Figure 2, Item 3). Install upper radiator baffle seal and plate (Figure 2, Item 1) on left and right baffle plates (Figure 2, Item 5) with two lockwashers (Figure 2, Item 12) and screws (Figure 2, Item 13). Install upper radiator baffle seal and plate (Figure 2, Item 1) on brush guard (Figure 2, Item 11) with four lockwashers (Figure 2, Item 9) and screws (Figure 2, Item 10).
13 12 1 2 3 4 5 6 7
11
8 5
10
9
M5118DAA
Figure 2. Radiator Baffles, Seals, and Plates Installation. END OF TASK END OF WORK PACKAGE
0562-3/4 blank
TM 9-2320-272-23-4
0563
FIELD MAINTENANCE CAB HOOD STOP BRACKET REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 285) Qty: 2 Shim (Volume 5, WP 0827, Table 1, Item 47) Equipment Condition Parking brake set. (TM 9-2320-272-10) Hood raised and secured. (TM 9-2320-272-10)
REMOVAL
NOTE
This procedure applies to both left and right stop brackets. Remove two locknuts (Figure 1, Item 4), stop bracket (Figure 1, Item 3), and shim (Figure 1, Item 2) from firewall (Figure 1, Item 1). Discard locknuts.
3 4
M9831DAA
Cab Hood Stop Bracket Removal.
0563-1
TM 9-2320-272-23-4
0563
INSTALLATION
NOTE
Install original shim or new shims as required to establish proper alignment between vehicle and stop bracket. Install shim (Figure 2, Item 2) and stop bracket (Figure 2, Item 3) on firewall (Figure 2, Item 1) with two locknuts (Figure 2, Item 4).
3 4
M5118-1DAA
Figure 2. Cab Hood Stop Bracket Installation. END OF TASK END OF WORK PACKAGE
0563-2
TM 9-2320-272-23-4
0564
FIELD MAINTENANCE HOOD BUMPER REPLACEMENT
REMOVAL
NOTE
This procedure applies to both left and right hood bumpers. Remove three locknuts (Figure 1, Item 3), screws (Figure 1, Item 4), washers (Figure 1, Item 5), and hood bumper (Figure 1, Item 1) from cab body (Figure 1, Item 2). Discard locknuts.
1 2 4 5 3
M5119DAA
Hood Bumper Removal.
0564-1
TM 9-2320-272-23-4
0564
INSTALLATION Install hood bumper (Figure 2, Item 1) on cab body (Figure 2, Item 2) with three washers (Figure 2, Item 5), screws (Figure 2, Item 4), and locknuts (Figure 2, Item 3).
1 2 4 5 3
M9830DAA
Hood Bumper Installation.
0564-2
TM 9-2320-272-23-4
0565
FIELD MAINTENANCE ENGINE HOOD REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Hoist Assembly Wrench, Torque, Click, Ratcheting, 1/2" Drive, 250 Ft-Lb (Volume 5, WP 0826, Table 1, Item 63) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 285) Qty: 2 Locknut (Volume 5, WP 0827, Table 1, Item 289) Qty: 1 Materials/Parts (cont.) Lockwasher (Volume 5, WP 0827, Table 1, Item 394) Qty: 4 Lockwasher (Volume 5, WP 0827, Table 1, Item 426) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10) Hood raised and secured. (TM 9-2320-272-10) Left and right splash shields removed. (TM 9-2320-272-10)
0565-1
TM 9-2320-272-23-4
0565
REMOVAL 1. Remove two locknuts (Figure 1, Item 3), washers (Figure 1, Item 6), screws (Figure 1, Item 5), washers (Figure 1, Item 6), and hood stop cables (Figure 1, Item 4) from radiator support brackets (Figure 1, Item 7). Discard locknuts. Disconnect wiring harness quick-disconnect (Figure 1, Item 2) from harness plug (Figure 1, Item 1). Remove locknut (Figure 1, Item 8), washer (Figure 1, Item 9), screw (Figure 1, Item 12), washer (Figure 1, Item 9), ground strap (Figure 1, Item 11), and lockwasher (Figure 1, Item 10) from inside left fender (Figure 1, Item 13). Discard locknut and lockwasher.
2. 3.
0565-2
TM 9-2320-272-23-4
0565
REMOVAL - Continued
4 1 3
6 7 2 6 5
9 10 11 9
13
12
Figure 1. Engine Hood Removal.
M5120DAA
0565-3
TM 9-2320-272-23-4
0565
REMOVAL - Continued 4. 5. 6. Attach chain to hood support brackets and lifting device and raise hood (Figure 2, Item 1) until slack is removed. Remove hood retaining bar (Figure 2, Item 2) from bumper bracket (Figure 2, Item 6) and stow on hood stowage bracket (Figure 2, Item 6) (TM 9-2320-272-10). Remove four screws (Figure 2, Item 8), lockwashers (Figure 2, Item 7), and mounting plate (Figure 2, Item 5) from front crossmember (Figure 2, Item 4). Discard lockwashers.
WARNING
All personnel must stand clear during lifting operations. A shifting or swinging load may cause injury to personnel. Failure to comply may result in injury or death to personnel. 7. 8. Lift hood (Figure 2, Item 1) straight up and away from bumper (Figure 2, Item 9). Lower and remove hood (Figure 2, Item 1) from lifting device.
0565-4
TM 9-2320-272-23-4
0565
REMOVAL - Continued
4 7, 8 6 5
M10318DAA
Engine Hood Removal.
0565-5
TM 9-2320-272-23-4
0565
INSTALLATION 1. Attach chain to hood and lifting device and hoist onto front crossmember (Figure 3, Item 4).
WARNING
All personnel must stand clear during lifting operations. A shifting or swinging load may cause injury to personnel. Failure to comply may result in injury or death to personnel. 2. 3. 4. Install hood (Figure 3, Item 1) and mounting plate (Figure 3, Item 8) on front crossmember (Figure 3, Item 4) with four lockwashers (Figure 3, Item 7) and screws (Figure 3, Item 6). Secure hood (Figure 3, Item 1) to bumper bracket (Figure 3, Item 5) with hood retaining bar (Figure 3, Item 3) (TM 9-2320-272-10). Remove lifting device and chain from hood (Figure 3, Item 1).
0565-6
TM 9-2320-272-23-4
0565
4 8 5 6, 7
M10317DAA
Figure 3.
Engine Hood Installation.
0565-7
TM 9-2320-272-23-4
0565
INSTALLATION - Continued 5. Connect wiring harness quick-disconnect (Figure 4, Item 2) to harness plug (Figure 4, Item 1).
NOTE
Ensure ground strap is between washer and lockwasher. 6. Install lockwasher (Figure 4, Item 10) and ground strap (Figure 4, Item 11) on inside left fender (Figure 4, Item 13) with washer (Figure 4, Item 9), screw (Figure 4, Item 12), washer (Figure 4, Item 9), and locknut (Figure 4, Item 8). Install two hood stop cables (Figure 4, Item 4) on radiator support brackets (Figure 4, Item 7) with two washers (Figure 4, Item 6), screws (Figure 4, Item 5), washers (Figure 4, Item 6), and locknut (Figure 4, Item 3).
7.
0565-8
TM 9-2320-272-23-4
0565
4 1 3
6 7 2 6 5
9 10 11 9
13
12
Figure 4. Engine Hood Installation.
M5123DAA
END OF TASK
0565-9
TM 9-2320-272-23-4
0565
ADJUSTMENT 1. Close hood (Figure 5, Item 1) and check clearance at top and sides of hood and cowl (Figure 5, Item 2). Clearance should be 1/4 to 3/4 in. (0.64 to 1.9 cm) and equal at both top and bottom of hood. Loosen four screws (Figure 5, Item 4) at frame crossmember (Figure 5, Item 3). Position hood (Figure 5, Item 1) until proper clearance is obtained. Tighten four screws (Figure 5, Item 4) 100 lb-ft (136 Nm).
2. 3. 4.
0565-10
TM 9-2320-272-23-4
0565
ADJUSTMENT - Continued
3 4
Figure 5. END OF TASK Engine Hood Adjustment.
M5124DAA
0565-11/12 blank
TM 9-2320-272-23-4
0565
FOLLOW-ON MAINTENANCE Install left and right splash shields. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0565-12
TM 9-2320-272-23-4
0566
FIELD MAINTENANCE WINDSHIELD STOP BRACKET AND LATCH REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 282) Qty: 4 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Hood raised and secured. (TM 9-2320-272-10)
REMOVAL 1. Remove two locknuts (Figure 1, Item 7), screws (Figure 1, Item 2), and windshield latch (Figure 1, Item 8) from hood (Figure 1, Item 1). Discard locknuts.
NOTE
Hood insulation must be pulled back to gain access to nuts and reinforcement plates. 2. Remove two locknuts (Figure 1, Item 6), screws (Figure 1, Item 3), reinforcement plate (Figure 1, Item 5), and windshield stop bracket (Figure 1, Item 4) from hood (Figure 1, Item 1). Discard locknuts.
3 8 4
7
Figure 1. Windshield Stop Bracket and Latch Removal. END OF TASK
M5125DAA
0566-1
TM 9-2320-272-23-4
0566
INSTALLATION 1. 2. Install windshield stop bracket (Figure 2, Item 4) and reinforcement plate (Figure 2, Item 5) on hood (Figure 2, Item 1) with two screws (Figure 2, Item 3) and locknuts (Figure 2, Item 6). Install windshield latch (Figure 2, Item 8) on hood (Figure 2, Item 1) with two screws (Figure 2, Item 2) and locknuts (Figure 2, Item 7).
3 8 4
7
Figure 2. Windshield Stop Bracket and Latch Installation. END OF TASK END OF WORK PACKAGE
M5126DAA
0566-2
TM 9-2320-272-23-4
0567
FIELD MAINTENANCE ENGINE ACCESS COVER (IN-CAB) REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Adhesive, Silicone Rubber (Volume 5, WP 0825, Table 1, Item 2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Transmission console removed. (Volume 3, WP 0370) Winch console removed (if equipped). (Volume 3, WP 0370) Instrument cluster removed. (Volume 2, WP 0310)
0567-1
TM 9-2320-272-23-4
0567
REMOVAL 1. 2. Pull back cab floor insulation (Figure 1, Item 3), firewall insulation (Figure 1, Item 1), and access cover insulation (Figure 1, Item 6) to expose screw assembled washers (Figure 1, Item 7). Remove 16 screw assembled washers (Figure 1, Item 7) and access cover (Figure 1, Item 2) from firewall (Figure 1, Item 5) and cab floor (Figure 1, Item 4).
0567-2
TM 9-2320-272-23-4
0567
REMOVAL - Continued
6 7 1 5
2 3 4 3
M3245DAA
Engine Access Cover (In-Cab) Removal.
0567-3
TM 9-2320-272-23-4
0567
INSTALLATION 1. 2. Install access cover (Figure 2, Item 2) on firewall (Figure 2, Item 5) and cab floor (Figure 2, Item 4) with 16 screw assembled washers (Figure 2, Item 7). Apply adhesive to back side of cab floor insulation (Figure 2, Item 3), firewall insulation (Figure 2, Item 1), and access cover insulation (Figure 2, Item 6) and press into place on access cover (Figure 2, Item 2), firewall (Figure 2, Item 5), and cab floor (Figure 2, Item 4).
0567-4
TM 9-2320-272-23-4
0567
6 7 1 5
2 3 4 3
M9615DAA
Figure 2. Engine Access Cover (In-Cab) Installation. END OF TASK
0567-5
TM 9-2320-272-23-4
0567
FOLLOW-ON MAINTENANCE 1. 2. 3. Install instrument cluster. (Volume 2, WP 0310) Install winch console, if equipped. (Volume 3, WP 0370) Install transmission console. (Volume 3, WP 0370)
0567-6
TM 9-2320-272-23-4
0568
FIELD MAINTENANCE FRONT CAB MOUNT REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Insulator Inactive Materials/Parts (cont.) (Volume 5, WP 0827, Table 1, Item 266) Qty: 2 Locknut (Volume 5, WP 0827, Table 1, Item 289) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0568-1
TM 9-2320-272-23-4
0568
REMOVAL
NOTE
This procedure applies to both right and left front cab mounts. 1. 2. 3. Turn jacking screw (Figure 1, Item 9) until cab weight is supported. Remove locknut (Figure 1, Item 7), washer (Figure 1, Item 6), and insulator lower half (Figure 1, Item 5) from cab bracket (Figure 1, Item 1). Discard locknut and insulator. Remove screw (Figure 1, Item 2), washer (Figure 1, Item 3), and insulator upper half (Figure 1, Item 4). Discard insulator.
0568-2
TM 9-2320-272-23-4
0568
REMOVAL - Continued
3 4 5 6
7 9
M5196DAA
Front Cab Mount Removal.
0568-3
TM 9-2320-272-23-4
0568
INSTALLATION 1. 2. 3. 4. Place insulator upper half (Figure 2, Item 4) between cab bracket (Figure 2, Item 1) and frame bracket (Figure 2, Item 8). Install washer (Figure 2, Item 3) and screw (Figure 2, Item 2) on insulator upper half (Figure 2, Item 4), cab bracket (Figure 2, Item 1), and frame bracket (Figure 2, Item 8). Install insulator lower half (Figure 2, Item 5) on screw (Figure 2, Item 2) with washer (Figure 2, Item 6) and locknut (Figure 2, Item 7). Turn out jacking screw (Figure 2, Item 9) until it is secured all the way down.
0568-4
TM 9-2320-272-23-4
0568
3 4 5 6
7 9
M5197DAA
Front Cab Mount Installation.
0568-5/6 blank
TM 9-2320-272-23-4
0569
FIELD MAINTENANCE REAR CAB MOUNT REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Hoist Assembly Lifting Device Materials/Parts Insulator Inactive (Volume 5, WP 0827, Table 1, Item 266) Qty: 2 Locknut (Volume 5, WP 0827, Table 1, Item 289) Qty: 2 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Dump body raised (M929/A1/A2, M930/A1/A2). (TM 9-2320-272-10) Cab top removed. (TM 9-2320-272-10) Spare tire removed. (TM 9-2320-272-10)
0569-1
TM 9-2320-272-23-4
0569
REMOVAL 1. Pull back insulation and remove two locknuts (Figure 1, Item 7) and washers (Figure 1, Item 6) from cab (Figure 1, Item 1) and frame (Figure 1, Item 8). Discard locknuts.
CAUTION
Raise rear of cab enough to remove insulators. Damage to cab will result if raised too high. 2. 3. 4. Using overhead lifting device, raise cab (Figure 1, Item 1) until clear of insulators (Figure 1, Item 5). Remove two screws (Figure 1, Item 4), washers (Figure 1, Item 3), and springs (Figure 1, Item 2) from inside cab (Figure 1, Item 1). Remove two insulators (Figure 1, Item 5). Discard insulators.
4 3 2 1 5
7
M5198DAA
8
Figure 1. Rear Cab Mount Removal. END OF TASK
0569-2
TM 9-2320-272-23-4
0569
INSTALLATION 1. 2. 3. 4. Position two insulators (Figure 2, Item 5) between cab (Figure 2, Item 1) and frame (Figure 2, Item 8). Install two washers (Figure 2, Item 3), springs (Figure 2, Item 2), and screws (Figure 2, Item 4) through insulators (Figure 2, Item 5). Lower cab (Figure 2, Item 1) to frame (Figure 2, Item 7) and remove lifting device. Install two washers (Figure 2, Item 6) and locknuts (Figure 2, Item 7) on screws (Figure 2, Item 4) and tighten until washers (Figure 2, Item 3) are even with cab (Figure 2, Item 1) floor.
3 1 2 5 6
7 8
M5199DAA
Rear Cab Mount Installation.
0569-3
TM 9-2320-272-23-4
0569
FOLLOW-ON MAINTENANCE 1. 2. 3. Install spare tire. (TM 9-2320-272-10) Lower dump body (M929/A1/A2, M930/A1/A2). (TM 9-2320-272-10) Install cab top. (TM 9-2320-272-10)
0569-4
TM 9-2320-272-23-4
0570
FIELD MAINTENANCE CAB GRAB HANDLE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Adhesive, Silicone Rubber Materials/Parts (cont.) (Volume 5, WP 0825, Table 1, Item 2) Locknut (Volume 5, WP 0827, Table 1, Item 282) Qty: 4 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0570-1
TM 9-2320-272-23-4
0570
REMOVAL 1. 2. Lift insulation and cut two square patches to gain access to locknuts (Figure 1, Item 5) and reinforcing plates (Figure 1, Item 4). Save patches for installation. Remove four locknuts (Figure 1, Item 5), screws (Figure 1, Item 1), two reinforcing plates (Figure 1, Item 4), and grab handle (Figure 1, Item 2) from cab (Figure 1, Item 3). Discard locknuts.
3 4 5
1 4
M5154DAA
Figure 1. Cab Grab Handle Removal. END OF TASK
0570-2
TM 9-2320-272-23-4
0570
INSTALLATION 1. 2. Install grab handle (Figure 2, Item 2) on cab (Figure 2, Item 3) with four screws (Figure 2, Item 1), two reinforcing plates (Figure 2, Item 4), and four locknuts (Figure 2, Item 5). Install insulation on cab (Figure 2, Item 3) with silicone rubber adhesive.
3 4 5
1 4
M5155DAA
Cab Grab Handle Installation.
0570-3/4 blank
TM 9-2320-272-23-4
0571
FIELD MAINTENANCE VENT DOOR WEATHER SEAL REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Adhesive, Silicone Rubber (Volume 5, WP 0825, Table 1, Item 2) Vent Door Weather Seal Materials/Parts (cont.) (Volume 5, WP 0827, Table 1, Item 207) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0571-1
TM 9-2320-272-23-4
0571
REMOVAL 1. 2. Open vent door (Figure 1, Item 2). Remove vent door weather seal (Figure 1, Item 3) from vent door (Figure 1, Item 2). Discard weather seal.
M5184DAA
Figure 1. Vent Door Weather Seal Removal. END OF TASK
0571-2
TM 9-2320-272-23-4
0571
INSTALLATION
NOTE
Surface of cowl vent door opening must be clean, dry, and free of oil and grease before seal is installed. 1. 2. Apply thin coat of silicone rubber adhesive to mating surfaces of vent door (Figure 2, Item 2) and weather seal (Figure 2, Item 3) and allow to dry until tacky. Position weather seal (Figure 2, Item 3) into channel (Figure 2, Item 1) of vent door (Figure 2, Item 2) and press firmly into place.
M5185DAA
Vent Door Weather Seal Installation.
0571-3/4 blank
TM 9-2320-272-23-4
0572
FIELD MAINTENANCE CAB COWL VENT SCREEN AND DOOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin Materials/Parts (cont.) (Volume 5, WP 0827, Table 1, Item 332) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0572-1
TM 9-2320-272-23-4
0572
REMOVAL 1. 2. 3. 4. Remove nine screws (Figure 1, Item 1) and vent screen (Figure 1, Item 2) from cab cowl (Figure 1, Item 3). Spread vent door spring (Figure 1, Item 9) apart and disconnect vent door bracket (Figure 1, Item 7). Remove cotter pin (Figure 1, Item 8) from door pivot pin (Figure 1, Item 4). Discard cotter pin. Remove door pivot pin (Figure 1, Item 4) and vent door (Figure 1, Item 6) from hinge (Figure 1, Item 5) and cab cowl (Figure 1, Item 3).
4 1 2 3 5 6
M5186DAA
Cab Cowl Vent Screen & Door Removal.
0572-2
TM 9-2320-272-23-4
0572
INSTALLATION 1. 2. 3. Install vent door (Figure 2, Item 6) on cab cowl (Figure 2, Item 3) and hinge (Figure 2, Item 5) with door pivot pin (Figure 2, Item 4) and cotter pin (Figure 2, Item 8). Spread vent door spring (Figure 2, Item 9) apart and clamp to door hinge bracket (Figure 2, Item 7). Install vent screen (Figure 2, Item 2) on cab cowl (Figure 2, Item 3) with nine screws (Figure 2, Item 1).
4 1 2 3 5 6
M5187DAA
Figure 2. Cab Cowl Vent Screen & Door Installation. END OF TASK END OF WORK PACKAGE
0572-3/4 blank
TM 9-2320-272-23-4
0573
FIELD MAINTENANCE FRONT FENDERS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Front composite light removed. (Volume 2, WP 0327)
0573-1
TM 9-2320-272-23-4
0573
REMOVAL 1. 2. 3. Remove three screw assembled washers (Figure 1, Item 2) from fender reinforcement (Figure 1, Item 3) and hood (Figure 1, Item 1). Remove two screw assembled washers (Figure 1, Item 6) from fender (Figure 1, Item 4) and brushguard (Figure 1, Item 7). Remove eight screw assembled washers (Figure 1, Item 5) and fender (Figure 1, Item 4) from hood (Figure 1, Item 1).
7 6
M3241DAA
Figure 1. Front Fender Removal. END OF TASK INSTALLATION 1. Install fender (Figure 2, Item 4) on hood (Figure 2, Item 1) with eight screw assembled washers (Figure 2, Item 5).
0573-2
TM 9-2320-272-23-4
0573
INSTALLATION - Continued 2. 3. Install fender (Figure 2, Item 4) on brushguard (Figure 2, Item 7) with two screw assembled washers (Figure 2, Item 6). Install fender reinforcement (Figure 2, Item 3) on hood (Figure 2, Item 1) with three screw assembled washers (Figure 2, Item 2).
7 6
M9512DAA
Front Fender Installation.
Install front composite light. (Volume 2, WP 0327) END OF TASK END OF WORK PACKAGE
0573-3/4 blank
TM 9-2320-272-23-4
0574
FIELD MAINTENANCE FRONT FENDER EXTENSION REPLACEMENT
0574-1
TM 9-2320-272-23-4
0574
REMOVAL
NOTE
Front extension replacement is the same for both left and front fender extensions. This procedure covers the right fender extension. 1. 2. Remove five screw assembled washers (Figure 1, Item 5) from fender extension (Figure 1, Item 6) and splash shield (Figure 1, Item 4). Remove two locknuts (Figure 1, Item 3), screws (Figure 1, Item 1), and fender extension (Figure 1, Item 6) from support bracket (Figure 1, Item 2). Discard locknuts.
2 6
5 4
M5188DAA
Front Fender Extension Removal.
0574-2
TM 9-2320-272-23-4
0574
INSTALLATION 1. 2. Install fender extension (Figure 2, Item 6) on support bracket (Figure 2, Item 2) with two screws (Figure 2, Item 1) and locknuts (Figure 2, Item 3). Install fender extension (Figure 2, Item 6) on splash shield (Figure 2, Item 4) with five screw assembled washers (Figure 2, Item 5).
2 6
5 4
M5189DAA
Front Fender Extension Installation.
0574-3/4 blank
TM 9-2320-272-23-4
0575
FIELD MAINTENANCE FENDER SPLASH SHIELD REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 285) Qty: 4 Lockwasher (Volume 5, WP 0827, Table 1, Item 356) Qty: 3 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Fender extension removed. (WP 0574) Air cleaner intake pipe hose removed. (Volume 2, WP 0246)
0575-1
TM 9-2320-272-23-4
0575
REMOVAL
NOTE
Fender splash shield replacement is the same for both left and right side. This procedure covers the right fender splash shield. 1. 2. 3. Remove locknut (Figure 1, Item 8), screw (Figure 1, Item 6), and washer (Figure 1, Item 7) from splash shield (Figure 1, Item 5) and support brace (Figure 1, Item 11). Discard locknut. Remove three screws (Figure 1, Item 9) and lockwashers (Figure 1, Item 10) from splash shield (Figure 1, Item 5) and cab extension (Figure 1, Item 12). Discard lockwashers. Remove three locknuts (Figure 1, Item 4), washers (Figure 1, Item 3), and splash shield (Figure 1, Item 5) from screws (Figure 1, Item 2) and cab floor (Figure 1, Item 1). Discard locknuts.
1 2 12 11 3 4 5
10 9 8 7 6
M5190DAA
Fender Splash Shield Removal.
0575-2
TM 9-2320-272-23-4
0575
INSTALLATION 1. 2. 3. Install splash shield (Figure 2, Item 5) on cab floor (Figure 2, Item 1) and three screws (Figure 2, Item 2) with three washers (Figure 2, Item 3) and locknuts (Figure 2, Item 4). Install splash shield (Figure 2, Item 5) on cab extension (Figure 2, Item 12) with three lockwashers (Figure 2, Item 10) and screws (Figure 2, Item 9). Install splash shield (Figure 2, Item 5) on support brace (Figure 2, Item 11) with washer (Figure 2, Item 7), screw (Figure 2, Item 6), and locknut (Figure 2, Item 8).
1 2 12 11 3 4 5
10 9 8 7 6
M5191DAA
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2.
Fender Splash Shield Installation.
Install air cleaner intake pipe hose. (Volume 2, WP 0246) Install fender extension. (WP 0574)
0575-3/4 blank
TM 9-2320-272-23-4
0576
FIELD MAINTENANCE RADIATOR BRUSHGUARD REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) References TM 9-237 Equipment Condition Hood removed. (WP 0565) Blackout drive lamps removed. (Volume 2, WP 0326) Equipment Condition (cont.) Service headlamps removed. (Volume 2, WP 0325) Radiator baffles, seals, and plates removed. (Volume 2, WP 0282) OR Radiator baffles, seals, and plates removed. (Volume 2, WP 0283) Torsion bars and crossmember removed. (Volume 3, WP 0363)
0576-1
TM 9-2320-272-23-4
0576
REMOVAL 1. 2. Remove three screw assembled washers (Figure 1, Item 9) from left fender (Figure 1, Item 10) and brushguard (Figure 1, Item 3). Remove four nuts (Figure 1, Item 8), washers (Figure 1, Item 7), screws (Figure 1, Item 5), and wiring harness quick-disconnect (Figure 1, Item 6) from brushguard (Figure 1, Item 3).
NOTE
When performing Steps (3) through (7), note location of clamps for installation. 3. 4. Remove 12 screw assembled washers (Figure 1, Item 4) and harness clamps (Figure 1, Item 1) from brushguard (Figure 1, Item 3) and hood (Figure 1, Item 2). Remove six screw assembled washers (Figure 1, Item 12) and two upper hinge halves (Figure 1, Item 11) from brushguard (Figure 1, Item 3).
0576-2
TM 9-2320-272-23-4
0576
REMOVAL - Continued
10
12 11
Figure 1. Radiator Brushguard Removal.
M3242DAA
0576-3
TM 9-2320-272-23-4
0576
REMOVAL - Continued 5. 6. 7. Remove three screw assembled washers (Figure 2, Item 5) from right fender (Figure 2, Item 4) and brushguard (Figure 2, Item 6). Remove clamp (Figure 2, Item 8) and air duct (Figure 2, Item 9) from elbow (Figure 2, Item 7). Remove four nuts (Figure 2, Item 1), washers (Figure 2, Item 2), screws (Figure 2, Item 3), and elbow (Figure 2, Item 7) from brushguard (Figure 2, Item 6).
7 4
5
M3243DAA
Figure 2. Radiator Brushguard Removal.
0576-4
TM 9-2320-272-23-4
0576
REMOVAL - Continued 8. 9. Remove ten nuts (Figure 3, Item 2), screw assembled washers (Figure 3, Item 4), and brushguard (Figure 3, Item 3) from hood (Figure 3, Item 1). Inspect brushguard (Figure 3, Item 3) for cracks and breaks. If cracked or broken, replace or repair brushguard (TM 9-237).
1 2
2 3
4 4
M3243-1DAA M3243-1DAA
Radiator Brushguard Removal.
0576-5
TM 9-2320-272-23-4
0576
INSTALLATION 1. Install brushguard (Figure 4, Item 5) on hood (Figure 4, Item 4), aligning clamps (Figure 4, Item 3) on wiring harness (Figure 4, Item 2) in proper position, with ten screw assembled washers (Figure 4, Item 6) and nuts (Figure 4, Item 1).
2 1
3 1 4 5
6
M3244DAA
Figure 4. 2. 3. 4.
Radiator Brushguard Installation.
Install elbow (Figure 5, Item 7) on brushguard (Figure 5, Item 6) with four screws (Figure 5, Item 3), washers (Figure 5, Item 2), and nuts (Figure 5, Item 1). Install air duct (Figure 5, Item 9) on elbow (Figure 5, Item 7) with clamp (Figure 5, Item 8). Install brushguard (Figure 5, Item 6) on right fender (Figure 5, Item 4) with three screw assembled washers (Figure 5, Item 5).
0576-6
TM 9-2320-272-23-4
0576
7 4
5
M10136DAA
Figure 5.
Radiator Brushguard Installation.
0576-7
TM 9-2320-272-23-4
0576
INSTALLATION - Continued 5. 6. 7. 8. Install two upper hinge halves (Figure 6, Item 12) on brushguard (Figure 6, Item 3) with three screw assembled washers (Figure 6, Item 13). Install harness (Figure 6, Item 11) and harness clamps (Figure 6, Item 1) on hood (Figure 6, Item 2) with 12 screw assembled washers (Figure 6, Item 4). Install wiring harness quick-disconnect (Figure 6, Item 6) on brushguard (Figure 6, Item 3) with four screws (Figure 6, Item 5), washers (Figure 6, Item 7), and nuts (Figure 6, Item 8). Install three screw assembled washers (Figure 6, Item 9) on left fender (Figure 6, Item 10) and brushguard (Figure 6, Item 3).
0576-8
TM 9-2320-272-23-4
0576
11
10
13
12
Figure 6. END OF TASK 0576-9 Radiator Brushguard Installation.
M10135DAA
TM 9-2320-272-23-4
0576
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Install radiator baffles, seals, and plates. (Volume 2, WP 0282) OR Install radiator baffles, seals, and plates. (Volume 2, WP 0283) Install torsion bars and crossmember. (Volume 3, WP 0363) Install service headlamps. (Volume 2, WP 0325) Install blackout drive lamps. (Volume 2, WP 0326) Install hood. (WP 0565)
0576-10
TM 9-2320-272-23-4
0577
FIELD MAINTENANCE WINDSHIELD AND OUTER FRAME ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Lockwasher (Volume 5, WP 0827, Table 1, Item 383) Qty: 6 Lockwasher (Volume 5, WP 0827, Table 1, Item 392) Qty: 2 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Wiper blade, wiper motor, and wiper arm removed. (WP 0736)
0577-1
TM 9-2320-272-23-4
0577
REMOVAL
NOTE
Perform Steps (1) and (2) only on vehicles with hard top kit. 1. 2. 3. 4. 5. Remove two screws (Figure 1, Item 3) and lockwashers (Figure 1, Item 2) from roof (Figure 1, Item 7) and corner post (Figure 1, Item 5). Discard lockwashers. Remove four nuts (Figure 1, Item 1) and hook bolts (Figure 1, Item 4) from roof (Figure 1, Item 7) and windshield frame (Figure 1, Item 6). Remove hose clamp (Figure 1, Item 14) and wiper hose (Figure 1, Item 10) from copper air line (Figure 1, Item 13). Remove six screws (Figure 1, Item 8) and lockwashers (Figure 1, Item 9) from two windshield hinges (Figure 1, Item 12) and windshield frame (Figure 1, Item 6). Discard lockwashers. Open doors (Figure 1, Item 11) and remove windshield frame (Figure 1, Item 6) from two windshield hinges (Figure 1, Item 12).
1 2 3 9 8 7 4
14 12 5 13
10
6 11 11
M5129DAA
Windshield and Outer Frame Assembly Removal.
0577-2
TM 9-2320-272-23-4
0577
INSTALLATION 1. 2. With doors (Figure 2, Item 11) opened, align windshield frame (Figure 2, Item 6) on two windshield hinges (Figure 2, Item 12) and install with six lockwashers (Figure 2, Item 9) and screws (Figure 2, Item 8). Install wiper hose (Figure 2, Item 10) on copper air line (Figure 2, Item 13) with hose clamp (Figure 2, Item 14).
NOTE
Perform Steps (3) and (4) on vehicles with hardtop kit. 3. 4. Install roof (Figure 2, Item 7) on windshield frame (Figure 2, Item 6) with four hook bolts (Figure 2, Item 4) and nuts (Figure 2, Item 1). Install roof (Figure 2, Item 7) on corner post (Figure 2, Item 5) with two lockwashers (Figure 2, Item 2) and screws (Figure 2, Item 3).
4 7 5
12
14 13
10
11 6 11
M5130DAA
Figure 2. Windshield and Outer Frame Assembly Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install cab top on windshield. (TM 9-2320-272-10) Install wiper blade, wiper motor, and wiper arm. (WP 0736)
0577-3/4 blank
TM 9-2320-272-23-4
0578
FIELD MAINTENANCE WINDSHIELD FRAME ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Sealing Compound (Volume 5, WP 0825, Table 1, Item 57) Lockwasher (Volume 5, WP 0827, Table 1, Item 382) Qty: 4 Lockwasher (Volume 5, WP 0827, Table 1, Item 383) Qty: 6 Materials/Parts (cont.) Rubberstock Molding (Volume 5, WP 0827, Table 1, Item 50) Qty: 4 Screw Assembled Washer (Volume 5, WP 0827, Table 1, Item 169) Qty: 8 Equipment Condition Parking brake set. (TM 9-2320-272-10) Windshield wiper blade, wiper arm, and wiper motor removed. (WP 0736) Windshield removed. (WP 0577)
0578-1
TM 9-2320-272-23-4
0578
REMOVAL
NOTE
Left and right windshield frame assemblies are replaced the same. This procedure covers right windshield frame assembly. 1. 2. 3. 4. 5. 6. 7. 8. Secure windshield frame assembly (Figure 1, Item 6) in open position. Remove eight screw assembled washers (Figure 1, Item 1) from windshield hinge (Figure 1, Item 5) and windshield frame (Figure 1, Item 2). Discard screw assembled washers. Lower windshield frame assembly (Figure 1, Item 6). Remove two screws (Figure 1, Item 12) and spring washers (Figure 1, Item 14) from two friction lockarms (Figure 1, Item 11). Remove windshield frame assembly (Figure 1, Item 6) from windshield frame (Figure 1, Item 2). Remove two capnuts (Figure 1, Item 8), lockwashers (Figure 1, Item 7), screws (Figure 1, Item 10), and lock handle (Figure 1, Item 9) from windshield frame assembly (Figure 1, Item 6). Discard lockwashers. Remove seven screws (Figure 1, Item 4), windshield hinge (Figure 1, Item 5), and hinge seal (Figure 1, Item 3) from windshield frame assembly (Figure 1, Item 6). Remove two screws (Figure 1, Item 13), spring washers (Figure 1, Item 15), and friction lockarms (Figure 1, Item 11) from windshield frame assembly (Figure 1, Item 6).
5 2 1 3 4
14 15 13 12 11 10 9 8
M5131DAA
Figure 1. Windshield Frame Removal. END OF TASK
0578-2
TM 9-2320-272-23-4
0578
DISASSEMBLY
WARNING
Use eyeshields when replacing glass. Glass could shatter. Failure to comply may result in injury or death to personnel. 1. 2. 3. 4. 5. Remove two capnuts (Figure 2, Item 3), lockwashers (Figure 2, Item 4), screws (Figure 2, Item 5), and crosspiece (Figure 2, Item 2) from frame (Figure 2, Item 8). Discard lockwashers. Remove filler strip (Figure 2, Item 1) from crosspiece (Figure 2, Item 2). Discard filler strip. Remove four screws (Figure 2, Item 7) and lockwashers (Figure 2, Item 6) from frame (Figure 2, Item 8). Discard lockwashers. Remove two capnuts (Figure 2, Item 14), lockwashers (Figure 2, Item 13), screws (Figure 2, Item 11), and locking latch (Figure 2, Item 12) from frame (Figure 2, Item 8). Discard lockwashers. Remove glass (Figure 2, Item 9) and three filler strips (Figure 2, Item 10) from frame (Figure 2, Item 8). Discard filler strips.
2 3 4 5
8 6 7 10
9 14 8 13
Figure 2. END OF TASK Cab Windshield Disassembly.
11
12
M5133DAA
0578-3
TM 9-2320-272-23-4
0578
ASSEMBLY 1. 2. 3. 4. Position frame filler strip (Figure 3, Item 10) around glass (Figure 3, Item 9). Install glass (Figure 3, Item 9) with frame filler strip (Figure 3, Item 10) in frame (Figure 3, Item 8). Install crosspiece filler strip (Figure 3, Item 1) over glass (Figure 3, Item 9). Install crosspiece (Figure 3, Item 2) on glass (Figure 3, Item 9) and tap into position until screw holes are aligned with holes in frame (Figure 3, Item 8).
CAUTION
Do not overtighten crosspiece or windshield frame screws. Glass could be damaged. 5. 6. 7. 8. Secure crosspiece (Figure 3, Item 2) on frame (Figure 3, Item 8) with two screws (Figure 3, Item 5), lockwashers (Figure 3, Item 4), and capnuts (Figure 3, Item 3). Install four lockwashers (Figure 3, Item 6) and screws (Figure 3, Item 7) on frame (Figure 3, Item 8). Install locking latch (Figure 3, Item 12) on frame (Figure 3, Item 8) with two screws (Figure 3, Item 11), lockwashers (Figure 3, Item 13), and capnuts (Figure 3, Item 14). Trim crosspiece filler strip (Figure 3, Item 1) and frame filler strip (Figure 3, Item 10) even with frame (Figure 3, Item 8) and crosspiece (Figure 3, Item 2) edges.
2 3 4 5
8 6 7 10
9 14 8 13
Figure 3. Cab Windshield Assembly. END OF TASK INSTALLATION 1. 2.
11
12
M9994DAA
Install two friction lockarms (Figure 4, Item 11) on windshield frame assembly (Figure 4, Item 6) with two spring washers (Figure 4, Item 15) and screws (Figure 4, Item 13). Apply sealing compound to hinge seal (Figure 4, Item 3) and install on hinge (Figure 4, Item 5).
0578-4
TM 9-2320-272-23-4
0578
INSTALLATION - Continued 3. 4. 5. 6. 7. Install windshield hinge (Figure 4, Item 5) on windshield frame assembly (Figure 4, Item 6) with seven screws (Figure 4, Item 4). Install lock handle (Figure 4, Item 9) on windshield frame assembly (Figure 4, Item 6) with two screws (Figure 4, Item 10), lockwashers (Figure 4, Item 7), and capnuts (Figure 4, Item 8). Install two friction lockarms (Figure 4, Item 11) on windshield outer frame (Figure 4, Item 6) with two spring washers (Figure 4, Item 14) and screws (Figure 4, Item 12). Install windshield hinge (Figure 4, Item 5) on windshield frame (Figure 4, Item 2) with eight screw assembled washers (Figure 4, Item 1). Close and lock windshield frame assembly (Figure 4, Item 6).
5 2 1 3 4
14 15 13 12 11 10 9 8
M5132DAA
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install windshield. (WP 0577)
Windshield Frame Installation.
Install windshield wiper blade, wiper arm, and wiper motor. (WP 0736)
0578-5/6 blank
TM 9-2320-272-23-4
0579
FIELD MAINTENANCE CAB WINDSHIELD HINGE ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10)
0579-1
TM 9-2320-272-23-4
0579
REMOVAL
NOTE
Left and right hinge assemblies are replaced the same. This procedure covers right side. 1. 2. Remove three screws (Figure 1, Item 1) from windshield hinge (Figure 1, Item 3) and windshield frame (Figure 1, Item 2). Remove four screws (Figure 1, Item 5) and windshield hinge (Figure 1, Item 3) from cab (Figure 1, Item 4).
5
M5134DAA
Figure 1. Cab Windshield Hinge Removal. END OF TASK
0579-2
TM 9-2320-272-23-4
0579
INSTALLATION 1. 2. Install windshield hinge (Figure 2, Item 3) on cab (Figure 2, Item 4) with four screws (Figure 2, Item 5). Install windshield hinge (Figure 2, Item 3) on windshield frame (Figure 2, Item 2) with three screws (Figure 2, Item 1).
M5135DAA
Cab Windshield Hinge Installation.
0579-3/4 blank
TM 9-2320-272-23-4
0580
FIELD MAINTENANCE CAB INSULATION REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Adhesive, Silicone Rubber (Volume 5, WP 0825, Table 1, Item 1) Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Driver's seat removed. (WP 0582)
0580-1
TM 9-2320-272-23-4
0580
REMOVAL
NOTE
All insulation is removed the same way except where noted. This procedure covers replacement of left upper and engine access cover panels only. See Figure 1 for approximate locations of other cab installation. Clean all insulating material and adhesive from contact area. 1. 2. 3. Pull left rear upper panel insulation (Figure 1, Item 2) away from cab (Figure 1, Item 1) interior. Remove four screws (Figure 1, Item 6) and washers (Figure 1, Item 5) from engine access cover (Figure 1, Item 4). Pull engine access cover insulation (Figure 1, Item 3) away from engine access cover (Figure 1, Item 4).
1 2
5
M5200DAA
Figure 1. Cab Insulation Removal. END OF TASK
0580-2
TM 9-2320-272-23-4
0580
INSTALLATION 1. 2. Apply silicone rubber adhesive to foam side of insulation (Figure 2, Items 2 and 3) and install on cab (Figure 2, Item 1) interior and engine access cover (Figure 2, Item 4). Install four washers (Figure 2, Item 5) and screws (Figure 2, Item 6) on engine access cover (Figure 2, Item 4).
1 2
5
M10263DAA
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE Install driver's seat, if removed. (WP 0582) END OF TASK END OF WORK PACKAGE
Cab Insulation Installation.
0580-3/4 blank
TM 9-2320-272-23-4
0581
FIELD MAINTENANCE COMPANION SEAT CUSHION, BACKREST CUSHION, AND FRAME REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin Materials/Parts (cont.) (Volume 5, WP 0827, Table 1, Item 337) Qty: 2 Lockwasher (Volume 5, WP 0827, Table 1, Item 403) Qty: 14 Equipment Condition Parking brake set. (TM 9-2320-272-10)
REMOVAL 1. 2. Fold down backrest cushion frame (Figure 1, Item 2). Remove eight screws (Figure 1, Item 1), lockwashers (Figure 1, Item 5), washers (Figure 1, Item 4), and backrest cushion (Figure 1, Item 3) from backrest cushion frame (Figure 1, Item 2). Discard lockwashers.
5 4
M5201DAA
Figure 1. Companion Seat Cushion, Backrest Cushion, and Frame Removal.
0581-1
TM 9-2320-272-23-4
0581
REMOVAL - Continued 3. Remove six screws (Figure 2, Item 2), lockwashers (Figure 2, Item 3), washers (Figure 2, Item 4), and seat cushion (Figure 2, Item 1) from battery box cover (Figure 2, Item 5). Discard lockwashers.
1
4 3 2
M5151DAA
Figure 2.
Companion Seat Cushion, Backrest Cushion, and Frame Removal.
0581-2
TM 9-2320-272-23-4
0581
REMOVAL - Continued 4. 5. Remove two springs (Figure 3, Item 4) from two battery box cover extensions (Figure 3, Item 6) and backrest cushion frame (Figure 3, Item 1). Remove two cotter pins (Figure 3, Item 2), four washers (Figure 3, Item 3), two pins (Figure 3, Item 5), and backrest cushion frame (Figure 3, Item 1) from two battery box cover extensions (Figure 3, Item 6). Discard cotter pins.
3 7 6
5 4
M5148DAA
Figure 3. Companion Seat Cushion, Backrest Cushion, and Frame Removal. END OF TASK
0581-3
TM 9-2320-272-23-4
0581
INSTALLATION 1. 2. Install backrest cushion frame (Figure 4, Item 1) on battery box cover extensions (Figure 4, Item 5) with two pins (Figure 4, Item 6), four washers (Figure 4, Item 7), and two cotter pins (Figure 4, Item 2). Install two springs (Figure 4, Item 4) on battery box cover extensions (Figure 4, Item 6) and backrest cushion frame (Figure 4, Item 1).
3 7 6
5 4
M5149DAA
Figure 4. Companion Seat Cushion, Backrest Cushion, and Frame Installation.
0581-4
TM 9-2320-272-23-4
0581
INSTALLATION - Continued 3. Install seat cushion (Figure 5, Item 1) on battery box cover (Figure 5, Item 5) with six washers (Figure 5, Item 4), lockwashers (Figure 5, Item 4), and screws (Figure 5, Item 2).
1
4 3 2
M5151DAA
Figure 5. Companion Seat Cushion, Backrest Cushion, and Frame Installation.
0581-5
TM 9-2320-272-23-4
0581
INSTALLATION - Continued 4. Install backrest cushion (Figure 6, Item 2) on backrest cushion frame (Figure 6, Item 1) with eight washers (Figure 6, Item 3), lockwashers (Figure 6, Item 4), and screws (Figure 6, Item 5).
4 3
M9956DAA
Figure 6. Companion Seat Cushion, Backrest Cushion, and Frame Installation. END OF TASK END OF WORK PACKAGE
0581-6
TM 9-2320-272-23-4
0582
FIELD MAINTENANCE DRIVER'S SEAT, FRAME, AND BASE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Grease, Automotive and Artillery (Volume 5, WP 0825, Table 1, Item 28) Locknut (Volume 5, WP 0827, Table 1, Item 274) Qty: 8 Lockwasher (Volume 5, WP 0827, Table 1, Item 384) Qty: 4 Lockwasher (Volume 5, WP 0827, Table 1, Item 405) Qty: 8 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Driver's seatbelts removed. (Volume 5, WP 0790) Driver's seat cushion and backrest cushion removed. (WP 0583)
0582-1
TM 9-2320-272-23-4
0582
DRIVER'S SEAT REMOVAL 1. 2. Remove six screw assembled lockwashers (Figure 1, Item 1) from seat base (Figure 1, Item 3) and cab floor (Figure 1, Item 2). Discard screw assembled lockwashers. Slide driver's seat (Figure 1, Item 4) close to door opening.
NOTE
Assistant will help with Step (3). 3. Tilt driver's seat (Figure 1, Item 4) carefully out of door opening and remove.
0582-2
TM 9-2320-272-23-4
0582
DRIVER'S SEAT REMOVAL - Continued
2 3 1 1
M5140DAA
Driver's Seat Removal.
0582-3
TM 9-2320-272-23-4
0582
DRIVER'S SEAT INSTALLATION
NOTE
Assistant will help with Step (1). 1. 2. Position driver's seat (Figure 2, Item 4) so back faces rear of cab. Install seat base (Figure 2, Item 3) on cab floor (Figure 2, Item 2) with six screw assembled lockwashers (Figure 2, Item 1).
0582-4
TM 9-2320-272-23-4
0582
DRIVER'S SEAT INSTALLATION - Continued
2 3 1 1
M5141DAA
Driver's Seat Installation.
0582-5
TM 9-2320-272-23-4
0582
FRAME REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. Remove four locknuts (Figure 3, Item 2) and seat frame (Figure 3, Item 1) from adjusters (Figure 3, Item 3). Discard locknuts. Remove two screws (Figure 3, Item 17), four locknuts (Figure 3, Item 7), washers (Figure 3, Item 5), adjusters (Figure 3, Item 3), and washers (Figure 3, Item 15) from top frame (Figure 3, Item 14). Discard locknuts. Remove two nuts (Figure 3, Item 16), screws (Figure 3, Item 4), and shock absorber (Figure 3, Item 6) from seat base (Figure 3, Item 13). Remove four nuts (Figure 3, Item 19), lockwashers (Figure 3, Item 20), screws (Figure 3, Item 11), and two brackets (Figure 3, Item 21) from seat base (Figure 3, Item 13). Discard lockwashers. Remove spring (Figure 3, Item 18) from seat base (Figure 3, Item 13). Turn crank (Figure 3, Item 12) fully clockwise to remove tension from torque springs. Remove four nuts (Figure 3, Item 8), lockwashers (Figure 3, Item 9), and screws (Figure 3, Item 10) from seat base (Figure 3, Item 13). Discard lockwashers. Remove top frame (Figure 3, Item 14) from seat base (Figure 3, Item 13).
0582-6
TM 9-2320-272-23-4
0582
FRAME REMOVAL - Continued
17
16 18 13 15 14
4 5 6 7
13
8 9
20 21 19 11 12 11
10
13
M5142DAA
Figure 3. Driver's Seat Frame and Base Removal.
0582-7
TM 9-2320-272-23-4
0582
FRAME REMOVAL - Continued
NOTE
Tag strut for installation. 9. 10. Remove two nuts (Figure 4, Item 10), lockwashers (Figure 4, Item 9), screws (Figure 4, Item 5), and lower strut (Figure 4, Item 4) from top frame (Figure 4, Item 11). Discard lockwashers. Remove two nuts (Figure 4, Item 6), lockwashers (Figure 4, Item 7), torque rod (Figure 4, Item 8), sleeve (Figure 4, Item 12), two springs (Figure 4, Item 2), and upper strut (Figure 4, Item 1) from top frame (Figure 4, Item 11). Discard lockwashers. Remove pin (Figure 4, Item 16) from crank (Figure 4, Item 14). Remove crank (Figure 4, Item 14) and washer (Figure 4, Item 13) from swivel nut (Figure 4, Item 17) on bracket (Figure 4, Item 15).
11. 12.
END OF TASK INSPECTION AND REPAIR 1. 2. 3. 4. Inspect sheet metal parts, springs, brackets, struts, and pins for breaks, bends, and cracks. Replace if broken, bent, or cracked (TM 9-237). Inspect crank (Figure 4, Item 14), crank adjuster swivel nut (Figure 4, Item 17), torque rod (Figure 4, Item 8), and screws (Figure 4, Item 5) for damaged threads. Replace if damaged. Inspect shock absorber (Figure 4, Item 18) for damage. Replace if damaged. Inspect adjusters (Figure 4, Item 19) and crank (Figure 4, Item 14) for breaks, bends, and cracks. Replace if broken, bent, or cracked (TM 9-237).
0582-8
TM 9-2320-272-23-4
0582
INSPECTION AND REPAIR - Continued

18 4 5 6 12 6 7 10 9 8 7 15 16 13 11 17 14 11 11 14 19
1 2
M5144DAA
Driver's Seat Frame and Base.
0582-9
TM 9-2320-272-23-4
0582
INSTALLATION 1. 2. 3. Install washer (Figure 5, Item 13) and crank (Figure 5, Item 14) on top frame (Figure 5, Item 11) and swivel nut (Figure 5, Item 16) with pin (Figure 5, Item 15). Apply light coat of GAA grease to eight strut bushings (Figure 5, Item 3) and torque rod (Figure 5, Item 8). Install lower strut (Figure 5, Item 4) on top frame (Figure 5, Item 11) with two screws (Figure 5, Item 5), lockwashers (Figure 5, Item 9), and nuts (Figure 5, Item 10).
NOTE
Torque rod can be installed through one side only. 4. Install sleeve (Figure 5, Item 12), two springs (Figure 5, Item 2), and upper strut (Figure 5, Item 1) on top frame (Figure 5, Item 11) with torque rod (Figure 5, Item 8), two lockwashers (Figure 5, Item 7), and nuts (Figure 5, Item 6).
0582-10
TM 9-2320-272-23-4
0582
12 6 7 13 10 9 8 7 6 14 15
11
16
11
11
14
M5145DAA
Figure 5. Driver's Seat and Frame Installation.
0582-11
TM 9-2320-272-23-4
0582
INSTALLATION - Continued 5. 6. 7. 8. 9. 10. 11. Install lower strut (Figure 6, Item 12) and upper strut (Figure 6, Item 11) on seat base (Figure 6, Item 13) with four screws (Figure 6, Item 10), lockwashers (Figure 6, Item 9), and nuts (Figure 6, Item 8). Position spring (Figure 6, Item 22) on seat base (Figure 6, Item 13). Install two brackets (Figure 6, Item 20) on seat base (Figure 6, Item 13) with four screws (Figure 6, Item 21), lockwashers (Figure 6, Item 19), and nuts (Figure 6, Item 18). Install shock absorber Figure 6, Item 6) on top frame (Figure 6, Item 14) with screw (Figure 6, Item 4) and nut (Figure 6, Item 16). Install fixed end of shock absorber (Figure 6, Item 6) on seat base (Figure 6, Item 13) with screw (Figure 6, Item 4) and nut (Figure 6, Item 16). Install adjusters (Figure 6, Item 3) on top frame (Figure 6, Item 14) with two washers (Figure 6, Item 15), screws (Figure 6, Item 17), four washers (Figure 6, Item 5), and locknuts (Figure 6, Item 7). Install seat frame (Figure 6, Item 1) on adjusters (Figure 6, Item 3) with four locknuts (Figure 6, Item 2).
0582-12
TM 9-2320-272-23-4
0582
17
16 22 13 15 14
4 5 6 7
13
8 9
19 20 18 12 21 11
10
13
M5143DAA
Figure 6. Driver's Seat Frame and Base Installation. END OF TASK
0582-13
TM 9-2320-272-23-4
0582
FOLLOW-ON MAINTENANCE 1. 2. 3. Install driver seat. Install driver's seat cushion and backrest cushion. (WP 0583) Install driver's seatbelts. (Volume 5, WP 0790)
0582-14
TM 9-2320-272-23-4
0583
FIELD MAINTENANCE DRIVER'S SEAT CUSHION AND BACKREST CUSHION REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Lockwasher Materials/Parts (cont.) (Volume 5, WP 0827, Table 1, Item 384) Qty: 4 Equipment Condition Parking brake set. (TM 9-2320-272-10)
REMOVAL 1. 2. 3. Remove four screws (Figure 1, Item 5) and lockwashers (Figure 1, Item 6) from two brackets (Figure 1, Item 7) and seat cushion (Figure 1, Item 1). Discard lockwashers. Remove two seat brackets (Figure 1, Item 7) and washers (Figure 1, Item 2) from seat frame pins (Figure 1, Item 3). Remove seat cushion (Figure 1, Item 1) from seat frame (Figure 1, Item 4).
1
7 2
6 3 5
4
M9900DAA
Figure 1. Driver's Seat Cushion and Backrest Cushion Removal.
0583-1
TM 9-2320-272-23-4
0583
REMOVAL - Continued 4. 5. 6. Remove two screws (Figure 2, Item 6) from adjuster rod brackets (Figure 2, Item 7) and remove adjuster rod brackets. Remove two screws (Figure 2, Item 5) and upper mounting brackets (Figure 2, Item 4) from seat frame (Figure 2, Item 3). Remove backrest cushion (Figure 2, Item 1) and wear plate (Figure 2, Item 2) from seat frame (Figure 2, Item 3).
6 7
M5146DAA
Figure 2. Driver's Seat Cushion and Backrest Cushion Removal. END OF TASK
0583-2
TM 9-2320-272-23-4
0583
INSTALLATION 1. 2. Install wear plate (Figure 3, Item 2), backrest cushion (Figure 3, Item 1), and two adjuster rod brackets (Figure 3, Item 7) on seat frame (Figure 3, Item 3) with two screws (Figure 3, Item 6). Install two upper mounting brackets (Figure 3, Item 4) on seat frame (Figure 3, Item 3) and backrest cushion (Figure 3, Item 1) with two screws (Figure 3, Item 5).
6 7
M5147DAA
Figure 3.
Driver's Seat Cushion and Backrest Cushion Installation.
0583-3
TM 9-2320-272-23-4
0583
INSTALLATION - Continued 3. 4. 5. Install two seat brackets (Figure 4, Item 7) on seat cushion (Figure 4, Item 1) with four lockwashers (Figure 4, Item 6) and screws (Figure 4, Item 5). Position seat cushion (Figure 4, Item 1) on seat frame (Figure 4, Item 4). Install two seat brackets (Figure 4, Item 7) and washers (Figure 4, Item 2) on seat frame pins (Figure 4, Item 3).
1
7 2
6 3 5
4
M9901DAA
Driver's Seat Cushion and Backrest Cushion Installation.
0583-4
TM 9-2320-272-23-4
0584
FIELD MAINTENANCE MAP COMPARTMENT REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 285) Qty: 4 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0584-1
TM 9-2320-272-23-4
0584
REMOVAL 1. 2. 3. 4. 5. Fold companion seat backrest (Figure 1, Item 1) forward. Release two latches (Figure 1, Item 9) on battery box (Figure 1, Item 8). Raise battery box cover (Figure 1, Item 2) and secure with support rod (Figure 1, Item 10). Remove four locknuts (Figure 1, Item 7), screws (Figure 1, Item 4), and washers (Figure 1, Item 3) from map compartment risers (Figure 1, Item 6) and battery box cover (Figure 1, Item 2). Discard locknuts. Remove map compartment (Figure 1, Item 5) from battery box (Figure 1, Item 8).
1 2 2 3 4 5
10 7 8 6
8
M5152DAA
Figure 1. Map Compartment Removal. END OF TASK
0584-2
TM 9-2320-272-23-4
0584
INSTALLATION 1. 2. 3. Install map compartment (Figure 2, Item 5) on battery box cover (Figure 2, Item 2) with four washers (Figure 2, Item 3), screws (Figure 2, Item 4), and four locknuts (Figure 2, Item 7). Secure support rod (Figure 2, Item 10) in battery box (Figure 2, Item 8), lower battery box cover (Figure 2, Item 2), and secure with two latches (Figure 2, Item 9). Lower companion seat backrest (Figure 2, Item 1).
1 2 2 3 4 5
10 7 8 6
M5153DAA
Map Compartment Installation.
0584-3/4 blank
TM 9-2320-272-23-4
0585
FIELD MAINTENANCE VAN POWER CABLE REEL REPLACEMENT (M934A1/A2)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 285) Qty: 4 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Power cable removed. (TM 9-2320-272-10)
0585-1
TM 9-2320-272-23-4
0585
REMOVAL 1. Remove retaining pin (Figure 1, Item 2) from power cable reel (Figure 1, Item 5).
NOTE
Assistant will help with Step (2). 2. Remove four locknuts (Figure 1, Item 1), screws (Figure 1, Item 4), and power cable reel (Figure 1, Item 5) from mud flap support brackets (Figure 1, Item 3).
5 4
M9015DAA
Figure 1. Van Power Cable Reel Removal. END OF TASK
0585-2
TM 9-2320-272-23-4
0585
INSTALLATION 1. 2. Install power cable reel (Figure 2, Item 5) on mud flap support brackets (Figure 2, Item 3) with four screws (Figure 2, Item 4) and locknuts (Figure 2, Item 1). Install retaining pin (Figure 2, Item 2) on power cable reel (Figure 2, Item 5).
5 4
M9016DAA
Van Power Cable Reel Installation.
Install power cable. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0585-3/4 blank
TM 9-2320-272-23-4
0586
FIELD MAINTENANCE TOOLBOX AND STEPS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 282) Qty: 14 Locknut (Volume 5, WP 0827, Table 1, Item 285) Qty: 2 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0586-1
TM 9-2320-272-23-4
0586
REMOVAL 1. 2. 3. 4. 5. 6. Remove two locknuts (Figure 1, Item 18), screws (Figure 1, Item 16), and drain valve bracket (Figure 1, Item 17) from toolbox with step (Figure 1, Item 6). Discard locknuts. Remove two locknuts (Figure 1, Item 13), screws (Figure 1, Item 15), and toolbox support bracket (Figure 1, Item 14) from toolbox with step (Figure 1, Item 6). Discard locknuts. Release latch (Figure 1, Item 7) and open toolbox door (Figure 1, Item 12). Remove four locknuts (Figure 1, Item 10), screws (Figure 1, Item 8), washers (Figure 1, Item 9), toolbox (Figure 1, Item 4), and step (Figure 1, Item 6) from hangers (Figure 1, Item 11). Discard locknuts. Remove two screws (Figure 1, Item 3) and washers (Figure 1, Item 2) from step (Figure 1, Item 6) and toolbox (Figure 1, Item 4). Remove eight locknuts (Figure 1, Item 5), screws (Figure 1, Item 1), and step (Figure 1, Item 6) from toolbox (Figure 1, Item 4). Discard locknuts.
0586-2
TM 9-2320-272-23-4
0586
REMOVAL - Continued
1 6 5 2
4 18 17
16
10 15 14 13 12 11
M5192DAA
Toolbox and Steps Removal.
0586-3
TM 9-2320-272-23-4
0586
INSTALLATION 1. 2. 3. 4. 5. Install step (Figure 2, Item 6) on toolbox (Figure 2, Item 4) with eight screws (Figure 2, Item 1) and locknuts (Figure 2, Item 5). Install step (Figure 2, Item 6) on toolbox (Figure 2, Item 4) with two screws (Figure 2, Item 3) and washers (Figure 2, Item 2). Install toolbox (Figure 2, Item 4) with step (Figure 2, Item 6) on top of hangars (Figure 2, Item 11) with four washers (Figure 2, Item 9), screws (Figure 2, Item 8), and locknuts (Figure 2, Item 10). Install toolbox support bracket (Figure 2, Item 14) on toolbox (Figure 2, Item 4) with step (Figure 2, Item 6) with two screws (Figure 2, Item 15) and locknuts (Figure 2, Item 13). Install drain valve bracket (Figure 2, Item 17) on toolbox (Figure 2, Item 4) with step (Figure 2, Item 6) with two screws (Figure 2, Item 16) and locknuts (Figure 2, Item 18).
0586-4
TM 9-2320-272-23-4
0586
1 6 5 2
4 18 17
16
10 15 14 13 12 11
M5193DAA
Toolbox and Steps Installation.
0586-5/6 blank
TM 9-2320-272-23-4
0587
FIELD MAINTENANCE CARGO STOWAGE BOX REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 289) Qty: 4 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10)
0587-1
TM 9-2320-272-23-4
0587
REMOVAL 1. 2. Release two latches (Figure 1, Item 7) and open storage box door (Figure 1, Item 6). Remove four locknuts (Figure 1, Item 4), screws (Figure 1, Item 2), washers (Figure 1, Item 3), and stowage box (Figure 1, Item 1) from box hangers (Figure 1, Item 5). Discard locknuts.
M5299DAA
Figure 1. Cargo Stowage Removal. END OF TASK
0587-2
TM 9-2320-272-23-4
0587
INSTALLATION 1. 2. Install storage box (Figure 2, Item 1) on box hangers (Figure 2, Item 5) with four washers (Figure 2, Item 3), screws (Figure 2, Item 2), and locknuts (Figure 2, Item 4). Close stowage box door (Figure 2, Item 6) and secure with two latches (Figure 2, Item 7).
M5300DAA
Cargo Stowage Installation.
0587-3/4 blank
TM 9-2320-272-23-4
0588
FIELD MAINTENANCE CARGO BODY ASSEMBLY REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Chain Assembly (2) (Volume 5, WP 0826, Table 1, Item 15) High Boy Jack Stands (4) (Volume 5, WP 0826, Table 1, Item 24) Hoist Assembly Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 279) Qty: 8 Locknut (M923/A1/A2, M925/A1/A2) (Volume 5, WP 0827, Table 1, Item 275) Qty: 10 Locknut (M927/A1/A2, M928/A1/A2) (Volume 5, WP 0827, Table 1, Item 275) Qty: 20 Locknut (M923/A1/A2, M925/A1/A2) (Volume 5, WP 0827, Table 1, Item 279) Qty: 4 Locknut (M927/A1/A2, M928/A1/A2) (Volume 5, WP 0827, Table 1, Item 279) Qty: 16 Locknut (M923/A1/A2, M925/A1/A2) (Volume 5, WP 0827, Table 1, Item 280) Qty: 4 Sill, Wood (M923/A1/A2, M925/A1/A2) (Volume 5, WP 0827, Table 1, Item 32) Qty: 2 Sill, Wood (M927/A1/A2, M928/A1/A2) (Volume 5, WP 0827, Table 1, Item 35) Qty: 1 Materials/Parts (cont.) Sill, Wood (M927/A1/A2, M928/A1/A2) (Volume 5, WP 0827, Table 1, Item 36) Qty: 1 Sill, Wood (M927/A1/A2, M928/A1/A2) (Volume 5, WP 0827, Table 1, Item 37) Qty: 1 Sill, Wood (M927/A1/A2, M928/A1/A2) (Volume 5, WP 0827, Table 1, Item 38) Qty: 1 Personnel Required (3) References TM 43-0139 TM 9-237 TM 9-247 Equipment Condition Parking brake set. (TM 9-2320-272-10) Wheels chocked. (TM 9-2320-272-10) Front and side racks removed. (TM 9-2320-272-10) Cargo body cover bows removed. (WP 0731) Wheel splash guards and brackets removed. (WP 0596)
0588-1
TM 9-2320-272-23-4
0588
REMOVAL 1. Remove four locknuts (Figure 1, Item 5), washer (Figure 1, Item 6), outer support springs (Figure 1, Item 7), inner support springs (Figure 1, Item 4), and screws (Figure 1, Item 1) from two front upper holddown brackets (Figure 1, Item 2) and lower holddown brackets (Figure 1, Item 3). Discard locknuts.
3 2 1
7 4 6 5
M10282DAA
Figure 1. Front Holddown Brackets.
0588-2
TM 9-2320-272-23-4
0588
REMOVAL - Continued
NOTE
Extra-long wheelbase models (M927/A1/A2, M928/A1/A2) utilize six intermediate holddown brackets, 12 screws, and 12 locknuts. 2. Remove four locknuts (Figure 2, Item 4) and screws (Figure 2, Item 1) from four intermediate holddown brackets (Figure 2, Item 2) and lower holddown brackets (Figure 2, Item 3). Discard locknuts.
1 2
1 2 4
M3000DAA
Figure 2.
Intermediate Holddown Brackets.
0588-3
TM 9-2320-272-23-4
0588
REMOVAL - Continued 3. 4. 5. 6. Disconnect four wires (Figure 3, Item 10) from each of two rear composite lights (Figure 3, Item 5). Tag wires (Figure 3, Item 10) for installation. Remove eight locknuts (Figure 3, Item 7), screws (Figure 3, Item 9), and wire clamps (Figure 3, Item 8) from cargo body (Figure 3, Item 4). Discard locknuts. Wrap two utility chains (Figure 3, Item 3) around subframe beam (Figure 3, Item 12) and fasten hooks (Figure 3, Item 18) over utility chains (Figure 3, Item 3). Attach lifting device (Figure 3, Item 2) to center of utility chains (Figure 3, Item 3).
WARNING
Lifting device must have a weight capacity greater than the weight of the truck bed. Failure to comply may result in damage to equipment, injury, or death to personnel. All personnel must stand clear during lifting operations. A snapped cable, or swinging or shifting load, may occur. Failure to comply may result in injury or death to personnel.
NOTE
Mechanic will handle one guide line and direct hoisting operation. Assistant will handle other guide line. Second assistant will operate lifting device. 7. 8. 9. Connect two guide lines (Figure 3, Item 17) to front and rear lashing hooks (Figure 3, Item 1). Lift cargo body clear of frame (Figure 3, Item 6) and place on four shop stands (Figure 3, Item 16). Disconnect lifting device (Figure 3, Item 2), two utility chains (Figure 3, Item 3), and guide lines (Figure 3, Item 17) from cargo body (Figure 3, Item 4).
NOTE
Extra-long wheelbase models (M927/A1/A2, M928/A1/A2) utilize four wood sills, 20 washers, and 20 screws. 10. Remove ten locknuts (Figure 3, Item 15), lockwashers (Figure 3, Item 14), screws (Figure 3, Item 13), and two wood sills (Figure 3, Item 11) from cargo bed (Figure 3, Item 12). Discard locknuts, lockwashers, and wood sills.
0588-4
TM 9-2320-272-23-4
0588
REMOVAL - Continued
2 3 12 1 3 4
18 17
5 5 6
16 7 15 14 4
12 5 11 9 13 10
M3001DAA
Cargo Body Removal.
0588-5
TM 9-2320-272-23-4
0588
CLEANING AND INSPECTION
WARNING
Solvent cleaning compound is flammable and toxic. Do not use near an open flame and always have a fire extinguisher nearby when solvents are used. Use only in well-ventilated places, wear protective clothing, and dispose of cleaning rags in approved container. Failure to comply may result in damage to equipment, injury, or death to personnel. 1. 2. Clean cargo body with steam or wire brush and approved cleaning solvent (TM 9-247). Inspect cargo body for dents, cracks, breaks, and rust.
END OF TASK REPAIR 1. 2. Weld or straighten as necessary (TM 9-237). Strip and paint as necessary (TM 43-0139).
END OF TASK INSTALLATION 1. 2. 3. 4. Wrap two utility chains (Figure 4, Item 3) around subframe beam (Figure 4, Item 12) and fasten hooks (Figure 4, Item 18) over utility chains (Figure 4, Item 3). Connect two guide lines (Figure 4, Item 17) to front and rear lashing hooks (Figure 4, Item 1). Attach lifting device (Figure 4, Item 2) to center of utility chains (Figure 4, Item 3). Install two wood sills (Figure 4, Item 8) on cargo bed (Figure 4, Item 4) with ten screws (Figure 4, Item 9), lockwashers (Figure 4, Item 10), and locknuts (Figure 4, Item 11).
WARNING
Lifting device must have a weight capacity greater than the weight of the truck bed. Failure to comply may result in damage to equipment, injury, or death to personnel. All personnel must stand clear during lifting operations. A snapped cable, or swinging or shifting load, may occur. Failure to comply may result in injury or death to personnel.
NOTE
Mechanic will handle one guide line and direct hoisting operation. Assistant will handle other guide line. Second assistant will operate lifting device. 5. Hoist cargo body (Figure 4, Item 4) clear of shop stands (Figure 4, Item 12).
0588-6
TM 9-2320-272-23-4
0588
3 7 2 1 3 4 14
1 13
5 5 6
11 12 10 7
M3002DAA
Figure 4.
Cargo Body.
0588-7
TM 9-2320-272-23-4
0588
INSTALLATION - Continued 6. Lower cargo body (Figure 5, Item 3) onto frame (Figure 5, Item 11) while using a drift pin to align two front upper holddown brackets (Figure 5, Item 5) to lower holddown brackets (Figure 5, Item 6), and four intermediate holddown brackets (Figure 5, Item 13) to lower holddown brackets (Figure 5, Item 14). Place four outer support springs (Figure 5, Item 10) over inner support springs (Figure 5, Item 7), and position under lower holddown brackets (Figure 5, Item 6), and install with four screws (Figure 5, Item 4), washers (Figure 5, Item 9), and locknuts (Figure 5, Item 8). Tighten locknuts (Figure 5, Item 8) until length of springs (Figure 5, Items 7 and 10) are 6.75 in. 0.06 in. (171.45 mm 1.5 mm).
7.
NOTE
Extra-long wheelbase models (M927/A1/A2, M928/A1/A2) utilize six intermediate holddown brackets, 12 screws, and 12 locknuts. 8. 9. 10. 11. Place four screws (Figure 5, Item 12) through intermediate holddown brackets (Figure 5, Item 13) and lower holddown brackets (Figure 5, Item 14), and install four locknuts (Figure 5, Item 15). Disconnect lifting device (Figure 5, Item 1), utility chains (Figure 5, Item 2), and guide lines from cargo body (Figure 5, Item 3). Connect four wires (Figure 5, Item 19) to connectors (Figure 5, Item 20) on each of two composite lights (Figure 5, Item 21). Install eight wire clamps (Figure 5, Item 17) on cargo body (Figure 5, Item 3) with eight screws (Figure 5, Item 18) and locknuts (Figure 5, Item 16).
0588-8
TM 9-2320-272-23-4
0588
1 2 2 3
4 5
6 10 9 7 8 FRONT HOLDDOWN BRACKET
2 11 3 16
12
13
21 18
17
14 19 15 20 INTERMEDIATE HOLDDOWN BRACKET

M3004DAA
Cargo Body.
0588-9
TM 9-2320-272-23-4
0588
FOLLOW-ON MAINTENANCE 1. 2. 3. Install wheel splash guards and brackets. (WP 0596) Install cargo body cover bows. (WP 0731) Install front and side racks. (TM 9-2320-272-10)
0588-10
TM 9-2320-272-23-4
0589
FIELD MAINTENANCE CARGO TROOP SEAT REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin (Volume 5, WP 0827, Table 1, Item 334) Qty: 1 Cotter Pin (Volume 5, WP 0827, Table 1, Item 337) Qty: 5 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10)
0589-1
TM 9-2320-272-23-4
0589
REMOVAL
NOTE
M927/A1/A2 and M928/A1/A2 model trucks have six hinges per troop seat. The M923/A1/A2 and M925/A1/A2 have five hinges per troop seat as shown in this procedure. 1. 2. 3. Remove five cotter pins (Figure 1, Item 4) and hinge pins (Figure 1, Item 2) from hinges (Figure 1, Items 5 and 6). Discard cotter pins. Remove cotter pin (Figure 1, Item 11), washer (Figure 1, Item 10), and stabilizer bar (Figure 1, Item 9) from side rack (Figure 1, Item 1) and cargo bed (Figure 1, Item 8). Discard cotter pin. Remove two seat latches (Figure 1, Item 3), release, and lower troop seat (Figure 1, Item 7) from side rack (Figure 1, Item 1).
2 1
3 4 5
11
10
9 7
8
M5283DAA
Cargo Troop Seat Removal.
0589-2
TM 9-2320-272-23-4
0589
INSTALLATION 1. 2. 3. Align hinges (Figure 2, Item 6) of troop seat (Figure 2, Item 7) with hinges (Figure 2, Item 5) on side rack (Figure 2, Item 1) and install with five hinge pins (Figure 2, Item 2) and cotter pins (Figure 2, Item 4). Install stabilizer bar (Figure 2, Item 9) on side rack (Figure 2, Item 1) and cargo bed (Figure 2, Item 8) with washer (Figure 2, Item 10) and cotter pin (Figure 2, Item 11). Raise troop seat (Figure 2, Item 7) to stow position on side rack (Figure 2, Item 1) and install with two seat latches (Figure 2, Item 3).
2 1
3 4 5
11
10
9 7
8
M5284DAA
Cargo Troop Seat Installation.
0589-3/4 blank
TM 9-2320-272-23-4
0590
FIELD MAINTENANCE CARGO TAILGATE AND BUMPER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Chain Assembly (Volume 5, WP 0826, Table 1, Item 15) Hoist Assembly Materials/Parts Grease, Automotive and Artillery (Volume 5, WP 0825, Table 1, Item 28) Cotter Pin Materials/Parts (cont.) (Volume 5, WP 0827, Table 1, Item 342) Qty: 4 Locknut (Volume 5, WP 0827, Table 1, Item 277) Qty: 1 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Tailgate closed and secured. (TM 9-2320-272-10)
0590-1
TM 9-2320-272-23-4
0590
REMOVAL
NOTE
All tailgate bumpers are removed the same way. 1. 2. 3. Remove locknut (Figure 1, Item 5) and bumper (Figure 1, Item 6) from tailgate (Figure 1, Item 1). Discard locknut. Install chain (Figure 1, Item 4) on two steps (Figure 1, Item 2) and lifting device (Figure 1, Item 3). Remove four cotter pins (Figure 1, Item 10), pins (Figure 1, Item 7), and eight washers (Figure 1, Item 8) from tailgate hinges (Figure 1, Item 9). Discard cotter pins.
WARNING
All personnel must stand clear during lifting operations. A shifting or swinging load may cause injury to personnel. Failure to comply may result in injury or death to personnel. 4. 5. Remove two hooks (Figure 1, Item 12) from tailgate latches (Figure 1, Item 13) and raise tailgate (Figure 1, Item 1) away from cargo body (Figure 1, Item 11). Lower tailgate (Figure 1, Item 1) onto supports and remove chain (Figure 1, Item 4) and lifting device (Figure 1, Item 3) from two steps (Figure 1, Item 2).
0590-2
TM 9-2320-272-23-4
0590
REMOVAL - Continued
3 4
2 1
13 5 12 6
7 8 9 11 10
Figure 1. Cargo Tailgate and Bumper Removal. END OF TASK
8
M9929DAA
0590-3
TM 9-2320-272-23-4
0590
INSTALLATION 1. Install chain (Figure 2, Item 4) on two steps (Figure 2, Item 2) and lifting device (Figure 2, Item 3).
WARNING
All personnel must stand clear during lifting operations. A shifting or swinging load may cause injury to personnel. Failure to comply may result in injury or death to personnel. 2. 3. 4. 5. 6. Raise tailgate (Figure 2, Item 1) and position on cargo body (Figure 2, Item 11). Install two hooks (Figure 2, Item 12) in tailgate latches (Figure 2, Item 13). Install four pins (Figure 2, Item 7) on tailgate hinges (Figure 2, Item 9) with eight washers (Figure 2, Item 8) and four cotter pins (Figure 2, Item 10). Remove chain (Figure 2, Item 4) and lifting device (Figure 2, Item 3) from two steps (Figure 2, Item 2). Install bumper (Figure 2, Item 6) on tailgate (Figure 2, Item 1) with locknut (Figure 2, Item 5).
0590-4
TM 9-2320-272-23-4
0590
3 4
2 1
13 5 12 6
7 8 9 11 10
Figure 2. END OF TASK END OF WORK PACKAGE Cargo Tailgate and Bumper Installation.
8
M9930DAA
0590-5/6 blank
TM 9-2320-272-23-4
0591
FIELD MAINTENANCE DUMP TAILGATE CONTROL LINKAGE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin (Volume 5, WP 0827, Table 1, Item 344) Qty: 4 Locknut (Volume 5, WP 0827, Table 1, Item 269) Qty: 2 Materials/Parts (cont.) Locknut (Volume 5, WP 0827, Table 1, Item 313) Qty: 14 Woodruff Key (Volume 5, WP 0827, Table 1, Item 415) Qty: 2 Equipment Condition Parking brake set. (TM 9-2320-272-10) Dump body in lowered position. (TM 9-2320-272-10)
0591-1
TM 9-2320-272-23-4
0591
REMOVAL 1. 2. 3. 4. 5. Place tailgate control lever (Figure 1, Item 2) in OPEN position. Remove adjusting nut (Figure 1, Item 18) from threaded end of control rod (Figure 1, Item 13). Remove locknut (Figure 1, Item 20), screw (Figure 1, Item 21), clevis (Figure 1, Item 17), and washer (Figure 1, Item 19) from tailgate control lever (Figure 1, Item 2). Discard locknut. Remove locknut (Figure 1, Item 16) and screw (Figure 1, Item 14) and slide tailgate control lever (Figure 1, Item 2) off control rod (Figure 1, Item 13). Discard locknut. Remove woodruff key (Figure 1, Item 15) from control lever (Figure 1, Item 2). Discard woodruff key.
NOTE
Repeat Steps (2) through (5) for removal of control linkage at opposite side. Tailgate control linkage is identical on each side except for tailgate control lever. Tailgate control lever on left side has a hand control. Tailgate control lever on vehicle right side does not. 6. 7. Remove six locknuts (Figure 1, Item 22), screws (Figure 1, Item 24), and three crossshaft bearings (Figure 1, Item 3) from bearing supports (Figure 1, Item 23). Discard locknuts. Remove two cotter pins (Figure 1, Item 10), nuts (Figure 1, Item 11), link plate (Figure 1, Item 12), and link (Figure 1, Item 4) from control rod (Figure 1, Item 13), tailgate latch (Figure 1, Item 8), from dump body (Figure 1, Item 1). Discard cotter pins. Slide control rod (Figure 1, Item 13) from front of dump body (Figure 1, Item 1).
8.
NOTE
Repeat Steps (7) through (9) for removal of control linkage at opposite side of dump body. 9. Remove three locknuts (Figure 1, Item 5), washers (Figure 1, Item 6), screws (Figure 1, Item 9), and tailgate latch (Figure 1, Item 8) from hole (Figure 1, Item 7) in rear of dump body (Figure 1, Item 1). Discard locknuts.
0591-2
TM 9-2320-272-23-4
0591
REMOVAL - Continued
1 22 23 24
2 3 3
21
13 20 19 18 17 8 5 4 2 16 9 6 7
14
13
15
13
12
11
10
M5305DAA
Figure 1. Dump Tailgate Control Linkage Removal. END OF TASK
0591-3
TM 9-2320-272-23-4
0591
INSTALLATION 1. Insert bar end of tailgate latch (Figure 2, Item 8) through hole (Figure 2, Item 7) in dump body (Figure 2, Item 1) and install with three screws (Figure 2, Item 9), washers (Figure 2, Item 6), and locknuts (Figure 2, Item 5). Insert yoke end of control rod (Figure 2, Item 13) to tailgate latch (Figure 2, Item 8). Insert link (Figure 2, Item 4) through hole in tailgate latch (Figure 2, Item 8) and yoke side of control rod (Figure 2, Item 13). Insert link (Figure 2, Item 4) into hole in dump body (Figure 2, Item 1). Install link plate (Figure 2, Item 12) on link (Figure 2, Item 4) with two nuts (Figure 2, Item 11) and cotter pins (Figure 2, Item 10). Install three crossshaft bearings (Figure 2, Item 3) on control rod (Figure 2, Item 13). Position three crossshaft bearings (Figure 2, Item 3) against outer bearing brackets (Figure 2, Item 23) and install with six screws (Figure 2, Item 24) and locknuts (Figure 2, Item 22). Place tailgate control lever (Figure 2, Item 2) in OPEN position. Place woodruff key (Figure 2, Item 15) on tailgate control lever (Figure 2, Item 2). Install tailgate control lever (Figure 2, Item 2) on control rod (Figure 2, Item 13) with screw (Figure 2, Item 14) and locknut (Figure 2, Item 16). Place clevis (Figure 2, Item 17) on threaded end of control rod (Figure 2, Item 13) and install washer (Figure 2, Item 19) and clevis on tailgate control lever (Figure 2, Item 2) with screw (Figure 2, Item 21) and locknut (Figure 2, Item 20).
2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
NOTE
Repeat Steps (8) through (12) for tailgate control linkage at opposite side. 12. Install adjusting nut (Figure 2, Item 18) on threaded end of control rod (Figure 2, Item 13).
0591-4
TM 9-2320-272-23-4
0591
1 22 23 24
2 3 3
21
13 20 19 18 17 8 5 4 2 16 9 6 7
14
13
15
13
12
11
10
M5306DAA
Dump Tailgate Control Linkage Installation.
0591-5/6 blank
TM 9-2320-272-23-4
0592
FIELD MAINTENANCE DUMP TAILGATE ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Chain Assembly (Volume 5, WP 0826, Table 1, Item 15) Lifting Device Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10)
0592-1
TM 9-2320-272-23-4
0592
REMOVAL 1. 2. 3. Install chain on two steps (Figure 1, Item 3) and attach chain to lifting device. Place tailgate control lever in OPEN position (TM 9-2320-272-10). Remove two retaining pins (Figure 1, Item 2) from dump body (Figure 1, Item 1).
WARNING
All personnel must stand clear during lifting operations. A snapped chain, or shifting or swinging load, may result in injury to personnel. Failure to comply may result in injury or death to personnel. 4. 5. Remove tailgate (Figure 1, Item 4) from dump body (Figure 1, Item 1) and lower tailgate onto supports. Remove lifting device and chain from steps (Figure 1, Item 3).
0592-2
TM 9-2320-272-23-4
0592
REMOVAL - Continued
3 1 2 3
M5303DAA
Dump Tailgate Assembly Removal.
0592-3
TM 9-2320-272-23-4
0592
INSTALLATION 1. Install chain on two steps (Figure 2, Item 3) and attach chain to lifting device.
WARNING
All personnel must stand clear during lifting operations. A snapped chain, or shifting or swinging load, may result in injury to personnel. Failure to comply may result in injury or death to personnel. 2. 3. 4. 5. Raise tailgate (Figure 2, Item 4) and position on dump body (Figure 2, Item 1). Install two retaining pins (Figure 2, Item 2) on dump body (Figure 2, Item 1). Place tailgate control lever to LOCKED position (TM 9-2320-272-10). Remove lifting device and chain from steps (Figure 2, Item 3).
0592-4
TM 9-2320-272-23-4
0592
3 1 2 3
M5304DAA
Figure 2. Dump Tailgate Assembly Installation. END OF TASK END OF WORK PACKAGE
0592-5/6 blank
TM 9-2320-272-23-4
0593
FIELD MAINTENANCE CARGO BODY FRAME RAIL SILL REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Wrench, Torque, Click, Ratcheting, 1/2" Drive, 250 Ft-Lb (Volume 5, WP 0826, Table 1, Item 63) Materials/Parts Coating, Polyurethane, CARC Green 383 (Volume 5, WP 0825, Table 1, Item 20) Materials/Parts (cont.) Wood, Laminated, Decking: Red or White Oak (Volume 5, WP 0825, Table 1, Item 72) Wood Preservative (Volume 5, WP 0825, Table 1, Item 71) References TM 43-0139 Equipment Condition Cargo body assembly removed. (WP 0588)
REMOVAL 1. 2. Remove ten nuts (Figure 1, Item 1), washers (Figure 1, Item 2), screws (Figure 1, Item 3), and frame rail sill (Figure 1, Item 4) from cargo body (Figure 1, Item 5). Clean frame rail sill (Figure 1, Item 4).
5 4 3
M3006DAA
Frame Rail Sill Removal.
0593-1
TM 9-2320-272-23-4
0593
INSPECTION Inspect frame rail sill for rot, deterioration, cracks, or breaks. If defects are found, fabricate replacement. END OF TASK FABRICATION
NOTE
Steps (1) and (2) apply to M927/A1/A2 and M928/A1/A2 model vehicles. Steps (3) and (4) apply to M923/A1/A2 and M925/A1/A2 model vehicles. 1. 2. Cut frame rail sill (Figure 2, Item 1) to dimensions and drill five counterbore holes (Figure 2, Item 2) and three frame rest holes (Figure 2, Item 3) as shown. Seal and paint frame rail sill (Figure 2, Item 1) (TM 43-0139).
0.375 .01 IN. DIA. THROUGH (9.525 0.254 MM) 0.875 .02 IN. DIA. C BORE (22.225 MM) 1.50 IN. DIA. (38.1 MM) 0.25 .02 IN. DEEP (6.35MM) 0.312 IN. DEEP (7.925 MM) 3 HOLES 1 12.00 IN. (304.8 MM)
0.137 IN. (3.48 MM) 152.00 IN. (3,860.8 MM) 100.5 IN. (2,552.7 MM) 58.75 IN. (1,492.25 MM) 17.00 IN. (431.8 MM)
3 6.50 IN. (165.1 MM) 2.00 IN. (50.8 MM) 1 1.5 IN. (38.1 MM)
13.75 IN. (349.25 MM)
142.25 IN. (3,613.15 MM) 159.75 25 IN. (4,057.65 MM)
3.00 IN. (76.2 MM)
M3007DAA
Figure 2. Cargo Frame Fabrication.
0593-2
TM 9-2320-272-23-4
0593
FABRICATION - Continued 3. 4. Cut frame rail sill (Figure 3, Item 4) to dimensions and drill ten counterbore holes (Figure 3, Item 3) and three frame root holes (Figure 3, Item 1) as shown. Seal and paint frame rail sill (Figure 3, Item 4) (Refer to TM 43-0139).
1.00 IN. (25.4 MM)
0.375 .01 IN. DIA. THROUGH (9.525 0.254 MM) 0.875 .02 IN. DIA. C BORE (22.225 MM) 0.25 .02 IN. DEEP (6.35MM)
1.50 IN. DIA (38.1 MM) 0.312 IN. DEEP (7.925 MM) 3 HOLES
102.31 IN. (2,598.674 MM)
2.00 IN. (50.8 MM)
6.50 IN. (165.1 MM)
1.50 IN. (38.1 MM) 2.75 IN. (69.85 MM)
1.12 IN. (28.448 MM) 4 21.30 IN. (541.02 MM) 42.60 IN. (1,082.04 MM) 63.90 IN. (1,623.06 MM) 85.20 IN. (2,164.08 MM) 110.06 .25 IN. (2,795.52 6.35 MM)
3.38 IN. (85.852 MM)
22.25 IN. (565.15 MM)
0.25 IN. (6.35 MM)
80.00 IN. (2,032 MM) 60.00 IN. (1,524 MM) 40.00 IN. (1,016 MM) 20.00 IN. (508 MM)
1.12 IN. (28.448 MM) 2.75 IN. (69.85 MM) 2

20.00 IN. (508 MM)
125.62 .25 IN. (3,190.748 6.35 MM)

M3008DAA
Cargo Frame Fabrication.
0593-3
TM 9-2320-272-23-4
0593
INSTALLATION 1. 2. Position frame rail sill (Figure 4, Item 4) on cargo body (Figure 4, Item 5). Install frame rail sill (Figure 4, Item 4) on cargo body (Figure 4, Item 5) with ten screws (Figure 4, Item 3), lockwashers (Figure 4, Item 2), and nuts (Figure 4, Item 1), ensuring heads of screws rest in sill of counterbore. Tighten nuts 100 to 110 lb-ft. (11 to 12 Nm).
5 4 3
M3009DAA
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE Install cargo body assembly. (WP 0588) END OF TASK END OF WORK PACKAGE
Frame Rail Sill Installation.
0593-4
TM 9-2320-272-23-4
0594
FIELD MAINTENANCE DUMP BODY REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Chain Assembly (2) (Volume 5, WP 0826, Table 1, Item 15) High Boy Jack Stands (Volume 5, WP 0826, Table 1, Item 24) Hoist Assembly Wrench, Torque, Click, Ratcheting, 3/4" Drive, 600 Ft-Lb (Volume 5, WP 0826, Table 1, Item 61) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 279) Qty: 6 Materials/Parts (cont.) Locknut (Volume 5, WP 0827, Table 1, Item 285) Qty: 1 Locknut (Volume 5, WP 0827, Table 1, Item 313) Qty: 1 Personnel Required (3) References TM 43-0139 Volume 5, WP 0820 Equipment Condition Parking brake set. (TM 9-2320-272-10) Wheels chocked. (TM 9-2320-272-10)
0594-1
TM 9-2320-272-23-4
0594
REMOVAL
WARNING
Lifting device must have a weight capacity greater than the combined weight of the dump body. Failure to comply may result in injury or death to personnel. All personnel must stand clear during lifting operations. A snapped cable, or swinging or shifting load, may occur. Failure to comply may result in injury or death to personnel. Never work under dump body until safety braces are properly positioned. Dump body may suddenly lower. Failure to comply may result in injury or death to personnel. 1. 2. Place dump body (Figure 1, Item 1) in raised position (TM 9-2320-272-10). Place safety braces (Figure 1, Item 14) in proper position (TM 9-2320-272-10).
NOTE
Step (3) applies to both left and right thrust plates. 3. 4. 5. 6. 7. Remove locknut (Figure 1, Item 3) and screw (Figure 1, Item 5) from thrust plate (Figure 1, Item 2) and thrust plate pin (Figure 1, Item 4). Discard locknut. Remove safety braces (Figure 1, Item 14) and place dump body (Figure 1, Item 1) in lowest position (TM 9-2320-272-10). Wrap two utility chains around subframe beam (Figure 1, Item 6) and fasten hooks over utility chains. Attach lifting device to center of utility chains. Raise lifting device until slack is removed from chains.
WARNING
Ensure dump control lever is in the NEUTRAL position and has not moved. Failure to comply may result in injury or death to personnel.
NOTE
Steps (8) through (11) apply to both left and right sides. 8. 9. 10. 11. Remove thrust plate pin (Figure 1, Item 4) from thrust plate (Figure 1, Item 2) and roller arms (Figure 1, Item 15). Remove six locknuts (Figure 1, Item 13) from hinge bracket (Figure 1, Item 9). Discard locknuts. Remove locknut (Figure 1, Item 10), washer (Figure 1, Item 11), and screw (Figure 1, Item 12) from hinge bracket (Figure 1, Item 9). Discard locknut. Connect two guide lines to front and rear of body (Figure 1, Item 1).
0594-2
TM 9-2320-272-23-4
0594
REMOVAL - Continued
WARNING
All personnel must stand clear during lifting operations. A snapped chain, or shifting or swinging load, may result in injury to personnel. Failure to comply may result in injury or death to personnel.
NOTE
Mechanic will handle one guide line and direct hoisting operation. Assistant will handle other guide line. Second assistant will operate lifting device. 12. 13. 14. Lift dump body (Figure 1, Item 1) clear of subframe (Figure 1, Item 7) and place on shop stands. Remove six screws (Figure 1, Item 8) from dump body (Figure 1, Item 1). Remove guide lines, lifting device, and utility chains from dump body (Figure 1, Item 1).
7 1 3 4 5 6 13 14 15 2 15 11 10
M3010DAA
12
Dump Body Removal.
0594-3
TM 9-2320-272-23-4
0594
INSPECTION AND REPAIR 1. 2. Inspect dump body for breaks, dents, cracks, and rust. If breaks, dents, cracks, and rusted-through areas are found, repair (TM 43-0139). Clean and paint dump body as necessary (TM 43-0139).
END OF TASK INSTALLATION
WARNING
Lifting device must have a weight capacity greater than the combined weight of the dump body. Failure to comply may result in damage to equipment, injury, or death to personnel. Ensure dump control lever is in the NEUTRAL position and has not moved. Failure to comply may result in injury or death to personnel. 1. 2. 3. Wrap two utility chains around dump body (Figure 2, Item 1) and fasten hooks over utility chains. Attach lifting device to center of utility chains. Connect two guide lines to front and rear of body (Figure 2, Item 1).
0594-4
TM 9-2320-272-23-4
0594
M3011DAA
Figure 2.
Dump Body Installation.
0594-5
TM 9-2320-272-23-4
0594
WARNING
NOTE
Mechanic will handle one guide line and direct hoisting operation. Assistant will handle other guide line. Second assistant will operate lifting device. Steps (4) and (7) through (9) apply to both left and right sides. 4. 5. 6. 7. 8. 9. 10. Install six screws (Figure 3, Item 8) on left and right sides of dump body (Figure 3, Item 1). Hoist dump body (Figure 3, Item 1) clear of shop stand. Place dump body (Figure 3, Item 1) on subframe (Figure 3, Item 2). Install two brackets (Figure 3, Item 9) on six screws (Figure 3, Item 8) with six locknuts (Figure 3, Item 13). Tighten locknuts to 240 lb-ft (325 Nm). Install screw (Figure 3, Item 12), washer (Figure 3, Item 11), and locknut (Figure 3, Item 10) on each bracket (Figure 3, Item 9). Tighten locknut to 35 lb-ft (48 Nm). Align roller arms (Figure 3, Item 15) and thrust plates (Figure 3, Item 2) and install thrust plate pin (Figure 3, Item 4). Remove lifting device, utility chains, and guide lines from dump body (Figure 3, Item 7).
WARNING
Never work under dump body until safety braces are properly positioned. Dump body may suddenly lower. Failure to comply may result in injury or death to personnel. 11. 12. Place dump body (Figure 3, Item 7) in raised position (TM 9-2320-272-10). Place safety braces (Figure 3, Item 14) in proper position (TM 9-2320-272-10).
NOTE
Step (13) applies to both left and right thrust plates. 13. Install thrust plate pin (Figure 3, Item 4) on thrust plate (Figure 3, Item 2) with screw (Figure 3, Item 5) and locknut (Figure 3, Item 3). Tighten locknut to 35 lb-ft (48 Nm).
0594-6
TM 9-2320-272-23-4
0594
7 1 3 4 5 6 13 14 15 2 15 11 10
M3012DAA
12
Figure 3. END OF TASK FOLLOW-ON MAINTENANCE Lubricate dump body. (Volume 5, WP 0820) END OF TASK END OF WORK PACKAGE
Dump Body Installation.
0594-7/8 blank
TM 9-2320-272-23-4
0595
FIELD MAINTENANCE DUMP CAB PROTECTOR SHIELD REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Chain Assembly (Volume 5, WP 0826, Table 1, Item 15) Hoist Assembly Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 289) Qty: 19 Personnel Required (2) References TM 43-0139 References (cont.) TM 9-237 Volume 5, WP 0819 Equipment Condition Parking brake set. (TM 9-2320-272-10) Wheels chocked. (TM 9-2320-272-10)
0595-1
TM 9-2320-272-23-4
0595
REMOVAL 1. 2. Install two eyebolts (Figure 1, Item 6) into rear holes (Figure 1, Item 5) of cab protector (Figure 1, Item 2) with two washers (Figure 1, Item 4) and nuts (Figure 1, Item 3). Attach two utility chains to eyebolts (Figure 1, Item 6) and opposite ends of cab protector front support channel (Figure 1, Item 1).
NOTE
Mechanic will direct hoisting operation while assistant operates lifting device. 3. Attach lifting device to center of two utility chains and remove slack from utility chains.
1 2
5 6
M3015DAA
Figure 1. 4. 5. 6.
Dump Cab Protector Shield Removal.
Remove seven locknuts (Figure 2, Item 11), washers (Figure 2, Item 2), screws (Figure 2, Item 1), and washers (Figure 2, Item 2) from cab protector (Figure 2, Item 3) and dump body (Figure 2, Item 12). Discard locknuts. Remove eight locknuts (Figure 2, Item 13), washers (Figure 2, Item 14), and screws (Figure 2, Item 9) from cab protector (Figure 2, Item 3) and two dump body extension brackets (Figure 2, Item 10). Discard locknuts. Remove four locknuts (Figure 2, Item 4), washers (Figure 2, Item 5), and two screws (Figure 2, Items 7 and 8) from cab protector (Figure 2, Item 3) and dump body side support channel (Figure 2, Item 6). Discard locknuts.
0595-2
TM 9-2320-272-23-4
0595
REMOVAL - Continued
WARNING
All personnel must stand clear during lifting operations. A snapped chain, or shifting or swinging load, may result in injury to personnel. Failure to comply may result in injury or death to personnel. 7. 8. Remove cab protector (Figure 2, Item 3) from two dump body extension brackets (Figure 2, Item 10) and position on four shop stands. Remove lifting device and utility chains from cab protector (Figure 2, Item 3).
1 2 3 4 5
6 12 13 14
2 11 10 9 7 8
M3016DAA
Figure 2.
0595-3
TM 9-2320-272-23-4
0595
REMOVAL - Continued 9. Remove two nuts (Figure 3, Item 2), washers (Figure 3, Item 3), and eyebolts (Figure 3, Item 5) from holes (Figure 3, Item 4) in cab protector (Figure 3, Item 1).
4 5
M3017DAA
Figure 3. END OF TASK INSPECTION AND REPAIR 1. 2.
Insect cab protector for breaks, dents, and rust. (Volume 5, WP 0819) If breaks, dents, and rusted-through areas are found, repair (TM 9-237). Clean and paint as necessary (TM 43-0139).
END OF TASK
0595-4
TM 9-2320-272-23-4
0595
INSTALLATION 1. 2. Install two eyebolts (Figure 4, Item 6) into rear holes (Figure 4, Item 5) of cab protector (Figure 4, Item 2) with two washers (Figure 4, Item 4) and nuts (Figure 4, Item 3). Attach two utility chains to eyebolts and opposite ends of cab protector front support channel (Figure 4, Item 1).
NOTE
Mechanic will direct hoisting operation while assistant operates lifting device. 3. Attach lifting device to center of two utility chains and remove slack from utility chains.
1 2
5 6
M3018DAA
Figure 4.
Dump Cab Protector Shield Installation.
0595-5
TM 9-2320-272-23-4
0595
WARNING
All personnel must stand clear during lifting operations. A snapped chain, or shifting or swinging load, may result in injury to personnel. Failure to comply may result in injury or death to personnel. 4. 5. Remove cab protector (Figure 5, Item 3) from four shop stands and position on two dump body extension brackets (Figure 5, Item 10). Using a drift pin, align mounting holes and install cab protector (Figure 5, Item 3) on two dump body extension brackets (Figure 5, Item 10) with eight screws (Figure 5, Item 9), washers (Figure 5, Item 14), and locknuts (Figure 5, Item 13). Install cab protector (Figure 5, Item 3) on left and right dump body side support channel (Figure 5, Item 6) with two screws (Figure 5, Items 7 and 8), four washers (Figure 5, Item 5), and locknuts (Figure 5, Item 4). Install cab protector (Figure 5, Item 3) on dump body (Figure 5, Item 12) with seven washers (Figure 5, Item 2), screws (Figure 5, Item 1), washers (Figure 5, Item 2), and locknuts (Figure 5, Item 11). Remove lifting device and utility chains from cab protector (Figure 5, Item 3).
1 2 3 4 5
6. 7. 8.
6 12 13 14
2 11 10 9 7 8
M9992DAA
Figure 5.
0595-6
TM 9-2320-272-23-4
0595
INSTALLATION - Continued 9. Remove two nuts (Figure 6, Item 2), washers (Figure 6, Item 3), and eyebolts (Figure 6, Item 5) from holes (Figure 6, Item 4) in cab protector (Figure 6, Item 1).
4 5
M9993DAA
0595-7/8 blank
TM 9-2320-272-23-4
0596
FIELD MAINTENANCE CARGO UPPER WHEEL SPLASH GUARD REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 285) Qty: 10 Equipment Condition Parking brake set. (TM 9-2320-272-10) Lower splash guard removed. (WP 0734)
REMOVAL 1. 2. Remove three locknuts (Figure 1, Item 1), screws (Figure 1, Item 4), and upper splash guard (Figure 1, Item 3) from weld bracket (Figure 1, Item 2). Discard locknuts. Remove two locknuts (Figure 1, Item 7), screws (Figure 1, Item 6), and braces (Figure 1, Item 5) from weld bracket (Figure 1, Item 2). Discard locknuts.
6 3 4 5 5
M5287DAA
Figure 1. Upper Wheel Splash Guard Removal. END OF TASK
0596-1
TM 9-2320-272-23-4
0596
INSTALLATION 1. 2. Install two braces (Figure 2, Item 5) on weld bracket (Figure 2, Item 2) with two screws (Figure 2, Item 6) and locknuts (Figure 2, Item 7). Install upper splash guard (Figure 2, Item 3) on weld bracket (Figure 2, Item 2) with three screws (Figure 2, Item 4) and locknuts (Figure 2, Item 1).
6 3 4 5 5
M5288DAA
Figure 2. Upper Wheel Splash Guard Installation. END OF TASK FOLLOW-ON MAINTENANCE Install lower wheel splash guard. (WP 0734) END OF TASK END OF WORK PACKAGE
0596-2
TM 9-2320-272-23-4
0597
FIELD MAINTENANCE SIDE LOCKING PIN RETAINING CLIP REPLACEMENT
0597-1
TM 9-2320-272-23-4
0597
REMOVAL Remove locknut (Figure 1, Item 5), screw (Figure 1, Item 3), and retaining clip (Figure 1, Item 2) from welded bracket (Figure 1, Item 4) on dropside (Figure 1, Item 1). Discard locknut.
5 4
M5296DAA
Figure 1. Side Locking Pin Retaining Clip Removal. END OF TASK
0597-2
TM 9-2320-272-23-4
0597
INSTALLATION Install retaining clip (Figure 2, Item 2) on welded bracket (Figure 2, Item 4) on dropside (Figure 2, Item 1) with screw (Figure 2, Item 3) and locknut (Figure 2, Item 5).
5 4
M5295DAA
Side Locking Pin Retaining Clip Installation.
0597-3/4 blank
TM 9-2320-272-23-4
0598
FIELD MAINTENANCE TAILGATE PERSONNEL STEP REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 289) Qty: 2 Equipment Condition Parking brake set. (TM 9-2320-272-10) Tailgate closed and secured. (TM 9-2320-272-10)
0598-1
TM 9-2320-272-23-4
0598
REMOVAL
NOTE
Left and right tailgate personnel steps are replaced the same. This procedure covers the left tailgate personnel step. Remove two locknuts (Figure 1, Item 5), screws (Figure 1, Item 2), plate (Figure 1, Item 4), and personnel step (Figure 1, Item 3) from tailgate (Figure 1, Item 1). Discard locknuts. END OF TASK INSTALLATION Install personnel step (Figure 1, Item 3) and plate (Figure 1, Item 4), on tailgate (Figure 1, Item 1) with two screws (Figure 1, Item 2) and locknuts (Figure 1, Item 5).
4 5
M5301DAA
Tailgate Personnel Step Replacement.
0598-2
TM 9-2320-272-23-4
0599
FIELD MAINTENANCE VAN REAR DOOR AND SIDE DOOR WINDOW REPLACEMENT
REMOVAL Remove 21 screws (Figure 1, Item 3) and door window frame (Figure 1, Item 1) from door (Figure 1, Item 2). END OF TASK INSTALLATION Install door window frame (Figure 1, Item 1) on door (Figure 1, Item 2) with 21 screws (Figure 1, Item 3).
M5308DAA
Van Rear Door and Side Door Window Replacement.
0599-1
TM 9-2320-272-23-4
0599
FOLLOW-ON MAINTENANCE Retract and secure van body (side door window only). (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0599-2
TM 9-2320-272-23-4
0600
FIELD MAINTENANCE WINDOW BRUSH GUARD REPLACEMENT
0600-1
TM 9-2320-272-23-4
0600
REMOVAL 1. 2. Release two latches (Figure 1, Item 4) and brush guard (Figure 1, Item 3) from window frame (Figure 1, Item 1). Remove two setscrews (Figure 1, Item 6) and hinge pins (Figure 1, Item 5) from hinges (Figure 1, Item 2) and brush guard (Figure 1, Item 3) from window frame (Figure 1, Item 1).
5 1 2 2 6
M5320DAA
Figure 1. Window Brush Guard Removal. END OF TASK
0600-2
TM 9-2320-272-23-4
0600
INSTALLATION 1. 2. 3. Position brush guard (Figure 2, Item 3) on window frame (Figure 2, Item 1) and two hinges (Figure 2, Item 2). Insert two hinge pins (Figure 2, Item 5) through hinges (Figure 2, Item 2) and install with two setscrews (Figure 2, Item 6). Secure brush guard (Figure 2, Item 3) on window frame (Figure 2, Item 1) with two latches (Figure 2, Item 4).
5 1 2 2 6
M5321DAA
Window Brush Guard Installation.
0600-3/4 blank
TM 9-2320-272-23-4
0601
FIELD MAINTENANCE REAR DOOR REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Adhesive, Silicone Rubber (Volume 5, WP 0825, Table 1, Item 2) Caulking Compound (Volume 5, WP 0825, Table 1, Item 14) Cotter Pin (Volume 5, WP 0827, Table 1, Item 338) Qty: 3 Gasket (Volume 5, WP 0827, Table 1, Item 23) Qty: 1 Locknut (Volume 5, WP 0827, Table 1, Item 320) Qty: 4 Lockwasher (Volume 5, WP 0827, Table 1, Item 403) Qty: 6 Rivet (Volume 5, WP 0827, Table 1, Item 309) Qty: 7 Materials/Parts (cont.) Rivet (Volume 5, WP 0827, Table 1, Item 310) Qty: 3 Seal (Volume 5, WP 0827, Table 1, Item 24) Qty: 1 Weather Seal (Volume 5, WP 0827, Table 1, Item 58) Qty: 1 Personnel Required (2) References TM 43-0213 Volume 5, WP 0819 Equipment Condition Parking brake set. (TM 9-2320-272-10) Ladder removed. (TM 9-2320-272-10) Rear door window removed. (WP 0599)
0601-1
TM 9-2320-272-23-4
0601
NOTE
Left and right doors are maintained basically the same way. This procedure covers the left door except where otherwise indicated. REMOVAL 1. 2. Remove two screws (Figure 1, Item 7), lockwashers (Figure 1, Item 6), strike (Figure 1, Item 5), and door check (Figure 1, Item 1) from door (Figure 1, Item 4). Discard lockwashers. Remove 15 screws (Figure 1, Item 3) and door (Figure 1, Item 4) from van body (Figure 1, Item 2).
7 6 5
M3036DAA
Rear Door Removal.
0601-2
TM 9-2320-272-23-4
0601
DISASSEMBLY 1. 2. 3. Remove two screws (Figure 2, Item 5) and angle bracket (Figure 2, Item 4) from outer panel (Figure 2, Item 3). Remove four screws (Figure 2, Item 6), lockwashers (Figure 2, Item 7), and clamp (Figure 2, Item 8) from outer panel (Figure 2, Item 3). Discard lockwashers. Remove four screws (Figure 2, Item 9), two screws (Figure 2, Item 1), washers (Figure 2, Item 2), bushings (Figure 2, Item 11), locknuts (Figure 2, Item 12), and rack (Figure 2, Item 10) from outer panel (Figure 2, Item 3). Discard locknuts.
1 2 11 10 3
9 12 8 7 6 5
M3037DAA
Figure 2.
Rear Door Disassembly.
0601-3
TM 9-2320-272-23-4
0601
DISASSEMBLY - Continued 4. Remove seven rivets (Figure 3, Item 17) and seal (Figure 3, Item 16) from door frame (Figure 3, Item 26). Discard rivets.
NOTE
Step (5) applies to left rear door only. 5. Remove four screws (Figure 3, Item 27), clip (Figure 3, Item 29), six screws (Figure 3, Item 31), and bracket (Figure 3, Item 30) from inner panel (Figure 3, Item 25).
2 6 7 8 9 10 25 26 11 27 28 13 29 14 11 30 12
3 4
24
23 22 21 20 19 18 32 5 4 15 17 16 31
9 7 8 6
M3038DAA
Figure 3. 6.
Remove two cotter pins (Figure 3, Item 11), screws (Figure 3, Item 7), lockwashers (Figure 3, Item 8), and rod (Figure 3, Item 9) from center case (Figure 3, Item 28) and two bolt and case assemblies (Figure 3, Item 5). Discard lockwashers and cotter pins. Remove pins (Figure 3, Items 13 and 14) and handle (Figure 3, Item 12) from center case (Figure 3, Item 28). Remove four screws (Figure 3, Item 10) and center case (Figure 3, Item 28) from inner panel (Figure 3, Item 25).
7. 8.
0601-4
TM 9-2320-272-23-4
0601
DISASSEMBLY - Continued 9. 10. 11. Remove eight screws (Figure 3, Item 6), two bolt and case assemblies (Figure 3, Item 5), and spacer plates (Figure 3, Item 4) from inner panel (Figure 3, Item 25). Remove 16 screws (Figure 3, Item 24), retainer (Figure 3, Item 23), seal (Figure 3, Item 22), hinge (Figure 3, Item 21), and seal (Figure 3, Item 20) from door frame (Figure 3, Item 26). Discard seals. Break adhesive seal and remove moldings (Figure 3, Items 1, 2, and 3) from inner panel (Figure 3, Item 25).
NOTE
Steps (12) and (13) apply to left rear door only. 12. 13. Break adhesive seal and remove weather seal (Figure 3, Item 18) from door frame (Figure 3, Item 26). Discard weather seal. Remove 35 screws (Figure 3, Item 32) and molding (Figure 3, Item 15) from door frame (Figure 3, Item 26).
NOTE
Steps (14) and (15) applies to right rear door only. 14. 15. Remove 34 screws (Figure 3, Item 32) and molding (Figure 3, Item 15) from door frame (Figure 3, Item 26). Remove three rivets (Figure 4, Item 3), handle (Figure 4, Item 2), and gasket (Figure 4, Item 1) from outer panel. Discard rivets.
1
M3039DAA
0601-5
TM 9-2320-272-23-4
0601
CLEANING AND INSPECTION 1. 2. 3. 4. For General Cleaning Instructions, refer to (Volume 5, WP 0819). Inspect all center case movable parts for proper operation. Replace any parts if damaged. Inspect rods for breaks and bends. Replace rods if damaged. Inspect moldings for cracks and bends. Replace moldings if damaged.
END OF TASK ASSEMBLY 1. Rustproof all inside surfaces and boxed-in areas (TB 43-0213).
NOTE
Apply caulking compound between exterior joints. Apply adhesive to rubber and metal surfaces for installation. Step (2) applies to right rear door only. 2. Install molding (Figure 5, Item 15) on door frame (Figure 5, Item 26) with 34 screws (Figure 5, Item 32).
NOTE
Steps (3) and (4) apply to left rear door only. 3. 4. 5. 6. 7. 8. 9. 10. Install molding (Figure 5, Item 15) on door frame (Figure 5, Item 26) with 35 screws (Figure 5, Item 32). Install weather seal (Figure 5, Item 18) on door frame (Figure 5, Item 26) with adhesive. Install moldings (Figure 5, Items 1, 2, and 3) on inner panel (Figure 5, Item 25) with adhesive. Install seal (Figure 5, Item 20), hinge (Figure 5, Item 21), seal (Figure 5, Item 22), and retainer (Figure 5, Item 23) on door frame (Figure 5, Item 26) with 16 screws (Figure 5, Item 24). Install two spacer plates (Figure 5, Item 4) and bolt and case assemblies (Figure 5, Item 5) on inner panel (Figure 5, Item 25) with eight screws (Figure 5, Item 6). Install center case (Figure 5, Item 28) on inner panel (Figure 5, Item 25) with four screws (Figure 5, Item 10). Install handle (Figure 5, Item 14) on center case (Figure 5, Item 28) with pins (Figure 5, Items 13 and 14). Install two rods (Figure 5, Item 9) on center case (Figure 5, Item 28) and two bolt and case assemblies (Figure 5, Item 5) with two cotter pins (Figure 5, Item 11), lockwashers (Figure 5, Item 8), and screws (Figure 6, Item 7). Install clip (Figure 5, Item 29) and bracket (Figure 5, Item 30) on outer panel (Figure 5, Item 19) with four screws (Figure 5, Item 27) and six screws (Figure 5, Item 31). Install seal (Figure 5, Item 16) on door frame (Figure 5, Item 26) with seven rivets (Figure 5, Item 17).
11. 12.
0601-6
TM 9-2320-272-23-4
0601
ASSEMBLY - Continued
2 6 7 8 9 10 25 26 11 27 28 13 29 14 11 30 12
3 4
24
23 22 21 20 19 18 32 5 4 15 17 16 31
9 7 8 6
M9933DAA
Figure 5.
Rear Door Assembly.
0601-7
TM 9-2320-272-23-4
0601
NOTE
Step (13) applies to right rear door only. 13. Install gasket (Figure 6, Item 1) and handle (Figure 6, Item 2) on outer panel with three rivets (Figure 6, Item 3).
1
M9934DAA
Figure 6. Rear Door Assembly. 14. 15. 16. Install rack (Figure 7, Item 10) on outer panel (Figure 7, Item 3) with four screws (Figure 7, Item 9), bushings (Figure 7, Item 11), washers (Figure 7, Item 2), two screws (Figure 7, Item 1), and locknuts (Figure 7, Item 12). Install clamp (Figure 7, Item 8) on outer panel (Figure 7, Item 3) with four screws (Figure 7, Item 6) and lockwashers (Figure 7, Item 7). Install two angle brackets (Figure 7, Item 4) on outer panel (Figure 7, Item 3) with two screws (Figure 7, Item 5).
0601-8
TM 9-2320-272-23-4
0601
1 2 11 10 3
9 12 8 7 6 5
M9935DAA
Rear Door Assembly.
0601-9
TM 9-2320-272-23-4
0601
INSTALLATION
NOTE
Align holes of door hinge with holes in van body for installation. Assistant will help with Step (1). 1. 2. Install door (Figure 8, Item 4) on van body (Figure 8, Item 2) with 15 screws (Figure 8, Item 3). Install door (Figure 8, Item 4) on door check (Figure 8, Item 1) with strike (Figure 8, Item 5), lockwasher (Figure 8, Item 6), and screw (Figure 8, Item 7).
7 6 5
M9936DAA
Figure 8. Rear Door Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install rear door window. (WP 0599) Install ladder. (TM 9-2320-272-10)
0601-10
TM 9-2320-272-23-4
0602
FIELD MAINTENANCE VAN SIDE DOORS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Lockwasher (Volume 5, WP 0827, Table 1, Item 403) Qty: 2 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Van body sides fully expanded and secured. (TM 9-2320-272-10) Side door window removed. (WP 0599)
0602-1
TM 9-2320-272-23-4
0602
REMOVAL
NOTE
Left and right side doors are replaced the same way. This procedure is for the left side door. 1. Remove two screws (Figure 1, Item 1), lockwashers (Figure 1, Item 2), bracket (Figure 1, Item 3), and door check lever (Figure 1, Item 4) from door (Figure 1, Item 5). Discard lockwashers.
NOTE
Assistant will help with Step (2). 2. Remove 15 screws (Figure 1, Item 6) and door (Figure 1, Item 5) from side panel of van body (Figure 1, Item 7).
0602-2
TM 9-2320-272-23-4
0602
REMOVAL - Continued
2 3 4
7 6 5
M4022DAA
Side Doors Removal.
0602-3
TM 9-2320-272-23-4
0602
INSTALLATION
NOTE
Assistant will help with Step (1). 1. 2. Install door (Figure 2, Item 5) on side panel of van body (Figure 2, Item 7) with 15 screws (Figure 2, Item 6). Install door check lever (Figure 2, Item 4) and bracket (Figure 2, Item 3) on door (Figure 2, Item 5) with two lockwashers (Figure 2, Item 2) and screws (Figure 2, Item 1).
2 3 4
7 6 5
M4022DAA
Figure 2. Side Doors Installation. END OF TASK
0602-4
TM 9-2320-272-23-4
0602
FOLLOW-ON MAINTENANCE 1. 2. Install side door window. (WP 0599) Retract van body sides. (TM 9-2320-272-10)
0602-5/6 blank
TM 9-2320-272-23-4
0603
FIELD MAINTENANCE VAN HINGED END PANEL REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Caulking Compound (Volume 5, WP 0825, Table 1, Item 14) Rivet (Volume 5, WP 0827, Table 1, Item 307) Qty: 12 Rivet (Volume 5, WP 0827, Table 1, Item 308) Qty: 18 Seal (Volume 5, WP 0827, Table 1, Item 17) Qty: 1 Materials/Parts (cont.) Seal (Volume 5, WP 0827, Table 1, Item 26) Qty: 1 Seal (Volume 5, WP 0827, Table 1, Item 237) Qty: 1 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Van body sides fully extended and secured. (TM 9-2320-272-10)
0603-1
TM 9-2320-272-23-4
0603
NOTE
All hinged end panels are removed the same way. This procedure covers the left rear hinged end panel. REMOVAL 1. Remove 16 screws (Figure 1, Item 4) from end panel hinge (Figure 1, Item 2) and side panel (Figure 1, Item 1).
NOTE
Assistant will help with Step (2). 2. Remove panel frame (Figure 1, Item 3) as an assembly from side panel (Figure 1, Item 1).
0603-2
TM 9-2320-272-23-4
0603
REMOVAL - Continued
3 2
M3044DAA
Hinged End Panel Removal.
0603-3
TM 9-2320-272-23-4
0603
DISASSEMBLY 1. 2. 3. 4. 5. Remove 16 screws (Figure 2, Item 17), hinge (Figure 2, Item 19), and seal (Figure 2, Item 20) from panel frame (Figure 2, Item 24). Discard seal. Remove 27 screws (Figure 2, Item 7), retainer (Figure 2, Item 9), and seal (Figure 2, Item 8) from panel frame (Figure 2, Item 24). Discard seal. Remove ten screws (Figure 2, Item 1), retainers (Figure 2, Items 2 and 3), and seal (Figure 2, Item 4) from channel (Figure 2, Item 5). Discard seal. Remove 18 rivets (Figure 2, Item 6), 20 screws (Figure 2, Item 16), and channels (Figure 2, Items 5 and 15) from outer skin (Figure 2, Item 11) and inner skin (Figure 2, Item 22). Discard rivets. Remove two screws (Figure 2, Item 14), strap (Figure 2, Item 13), and spacer plate (Figure 2, Item 12) from outer skin (Figure 2, Item 11).
NOTE
Perform Steps (6) and (7) only if skins are to be replaced. See CLEANING AND INSPECTION. Assistant will help with Steps (6) and (7). 6. 7. Remove 12 rivets (Figure 2, Item 10) and outer skin (Figure 2, Item 11) from panel frame (Figure 2, Item 24). Discard rivets. Remove 30 screws (Figure 2, Item 23), 18 screws (Figure 2, Item 21), and inner skin (Figure 2, Item 22) from panel frame (Figure 2, Item 24).
0603-4
TM 9-2320-272-23-4
0603
DISASSEMBLY - Continued
3 1 2
5 6 7
23 16 24 18 22 8 9 20 19 21
10
11
16 15 17 6
12 13 14
M3045DAA
Hinged End Panel Disassembly.
0603-5
TM 9-2320-272-23-4
0603
CLEANING AND INSPECTION 1. 2. 3. 4. 5. 6. Clean all parts. Inspect channels for cracks and bends. Replace channels if cracked or broken. Inspect retainers, spacer plate, and strap for bends and breaks. Replace retainers, spacer plate, or strap if bent or broken. Inspect hinge for cracks, breaks, corrosion, and proper operation. Inspect inner skin and outer skin for tears and punctures. Replace inner skin or outer skin if torn and punctured. Inspect panel frame for cracks and bends. Replace panel frame if cracked or broken.
END OF TASK ASSEMBLY
NOTE
Seal all exterior joints with caulking compound. Perform Steps (1) and (2) only if skins are to be replaced. Assistant will help with Steps (1) and (2). 1. 2. 3. 4. 5. 6. 7. Install inner skin (Figure 3, Item 22) on panel frame (Figure 3, Item 24) with 30 screws (Figure 3, Item 23) and 18 screws (Figure 3, Item 21). Install outer skin (Figure 3, Item 11) on panel frame (Figure 3, Item 24) with 12 rivets (Figure 3, Item 10). Install spacer plate (Figure 3, Item 12) and strap (Figure 3, Item 13) on outer skin (Figure 3, Item 11) with two screws (Figure 3, Item 14). Install channels (Figure 3, Items 5 and 15) on outer skin (Figure 3, Item 11) and inner skin (Figure 3, Item 22) with 18 rivets (Figure 3, Item 6) and 20 screws (Figure 3, Item 16). Install seal (Figure 3, Item 4) and retainers (Figure 3, Items 2 and 3) on channel (Figure 3, Item 5) with ten screws (Figure 3, Item 4). Install seal (Figure 3, Item 8) and retainer (Figure 3, Item 9) on outer skin (Figure 3, Item 11) with 27 screws (Figure 3, Item 7). Install seal (Figure 3, Item 20) and hinge (Figure 3, Item 19) on outer skin (Figure 3, Item 11) with 16 screws (Figure 3, Item 17).
0603-6
TM 9-2320-272-23-4
0603
3 1 2
5 6 7
23 16 24 18 22 8 9 20 19 21
10
11
16 15 17 6
12 13 14
M3047DAA
Hinged End Panel Assembly.
0603-7
TM 9-2320-272-23-4
0603
INSTALLATION
NOTE
Assistant will help you with Step (1). 1. 2. Position panel frame (Figure 4, Item 3) as an assembly on side panel (Figure 4, Item 1). Install end panel hinge (Figure 4, Item 2) on side panel (Figure 4, Item 1) with 16 screws (Figure 4, Item 4).
1
3 2
M3046DAA
Hinged End Panel Installation.
Retract van body sides. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0603-8
TM 9-2320-272-23-4
0604
FIELD MAINTENANCE VAN HINGED ROOF AND FLOOR COUNTERBALANCE CABLE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin (Volume 5, WP 0827, Table 1, Item 331) Qty: 1 Materials/Parts (cont.) Cotter Pin (Volume 5, WP 0827, Table 1, Item 341) Qty: 2 Wood Block Equipment Condition Parking brake set. (TM 9-2320-272-10) Van body fully expanded and secured (side door window only). (TM 9-2320-272-10)
0604-1
TM 9-2320-272-23-4
0604
REMOVAL
WARNING
Wear hand protection when handling cable. Do not handle cable with bare hands. Broken wires may be sharp. Failure to comply may result in injury or death to personnel. 1. Place a 1 in. (2.54-cm) block of wood (Figure 1, Item 3) between end of swivel hook (Figure 1, Item 1) and hinged roof (Figure 1, Item 2).
2
M5322DAA
Figure 1. 2. 3. 4. 5. 6. 7.
Hinge Roof and Floor Counterbalance Cable Removal.
Turn turnbuckle (Figure 2, Item 10) on hinged floor (Figure 2, Item 11) counterclockwise to decrease cable tension. Remove cotter pin (Figure 2, Item 18), pin (Figure 2, Item 2), and cable clevis (Figure 2, Item 1) from drop arm (Figure 2, Item 3). Discard cotter pin. Remove cotter pin (Figure 2, Item 4), pin (Figure 2, Item 5), and upper roller (Figure 2, Item 7) from mounting plate (Figure 2, Item 6). Discard cotter pin. Remove cotter pin (Figure 2, Item 15), pin (Figure 2, Item 14), and lower roller (Figure 2, Item 16) from folding arm (Figure 2, Item 13). Discard cotter pin. Disconnect lower cable end (Figure 2, Item 9) from turnbuckle (Figure 2, Item 10). Pull cable (Figure 2, Item 8) upward through two cable guides (Figure 2, Item 17) and remove from vehicle.
0604-2
TM 9-2320-272-23-4
0604
REMOVAL - Continued
18
3 4
6 7 17 16
15
14
13
10
10 12 11
M5324DAA
Hinge Roof and Floor Counterbalance Cable Removal.
0604-3
TM 9-2320-272-23-4
0604
INSTALLATION
NOTE
Perform Step (1) if installing new counterbalance cable. 1. 2. 3. Remove eye of turnbuckle (Figure 3, Item 10) from replacement cable end (Figure 3, Item 9). Thread cable (Figure 3, Item 8) through two cable guides (Figure 3, Item 16) and connect to turnbuckle (Figure 3, Item 10). Align lower folding arm (Figure 3, Item 12) with holes in corner post (Figure 3, Item 11) and install lower roller (Figure 3, Item 15) on folding arm (Figure 3, Item 12) with pin (Figure 3, Item 13) and cotter pin (Figure 3, Item 14). Ensure cable (Figure 3, Item 8) is behind lower roller. Install upper roller (Figure 3, Item 7) on mounting plate (Figure 3, Item 6) with pin (Figure 3, Item 5) and cotter pin (Figure 3, Item 4). Ensure cable (Figure 3, Item 8) is behind upper roller. Install cable clevis (Figure 3, Item 1) on drop arm (Figure 3, Item 3) with pin (Figure 3, Item 2) and cotter pin (Figure 3, Item 17).
4. 5.
0604-4
TM 9-2320-272-23-4
0604
17
3 4
6 7 16 15
14
13
12
10
10 11
M9701DAA
Figure 3. Hinge Roof and Floor Counterbalance Cable Installation.
0604-5
TM 9-2320-272-23-4
0604
INSTALLATION - Continued 6. Remove block of wood (Figure 4, Item 3) from swivel hook (Figure 4, Item 1) and hinged roof (Figure 4, Item 2).
2
M5323DAA
Figure 4. Hinge Roof and Floor Counterbalance Cable Installation. 7. Adjust cable tension; turn turnbuckle clockwise to increase tension and counterclockwise to decrease tension.
END OF TASK FOLLOW-ON MAINTENANCE Retract and secure van side panel (side door window only). (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0604-6
TM 9-2320-272-23-4
0605
FIELD MAINTENANCE VAN RETRACTABLE WINDOW REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin (Volume 5, WP 0827, Table 1, Item 341) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Van body fully expanded and secured (side door window only). (TM 9-2320-272-10) Van rear door and side door window removed. (WP 0599)
0605-1
TM 9-2320-272-23-4
0605
RETRACTABLE WINDOW REMOVAL 1. 2. 3. Open retractable window (Figure 1, Item 7). Remove cotter pin (Figure 1, Item 5) and regulator arm (Figure 1, Item 4) from frame bracket (Figure 1, Item 2). Discard cotter pin. Remove five screws (Figure 1, Item 1) and retractable window (Figure 1, Item 7) from outer frame (Figure 1, Item 3) and van body side panel (Figure 1, Item 6).
1 2 1 7
4 7
M5310DAA
Retractable Window Removal.
0605-2
TM 9-2320-272-23-4
0605
INSTALLATION 1. 2. 3. Install retractable window (Figure 2, Item 7) on outer frame (Figure 2, Item 3) and van body side panel (Figure 2, Item 6) with five screws (Figure 2, Item 1). Install regulator arm (Figure 2, Item 4) on frame bracket (Figure 2, Item 2) with cotter pin (Figure 2, Item 5). Close retractable window (Figure 2, Item 7).
1 2 1 7
4 7
M5311DAA
Retractable Window Installation.
0605-3
TM 9-2320-272-23-4
0605
RETRACTABLE WINDOW GLASS AND VAN DOOR WINDOW GLASS REMOVAL 1. 2. 3. Remove 18 screws (Figure 3, Item 3) and glass retainer (Figure 3, Item 2) from window frame (Figure 3, Item 1). Remove glass unit (Figure 3, Item 4) with seal (Figure 3, Item 5) from window frame (Figure 3, Item 1). Remove seal (Figure 3, Item 5) from two glass panes (Figure 3, Item 6).
0605-4
TM 9-2320-272-23-4
0605
RETRACTABLE WINDOW GLASS AND VAN DOOR WINDOW GLASS REMOVAL - Continued
1 2
4 6 5
M5312DAA
Window Glass Removal.
0605-5
TM 9-2320-272-23-4
0605
RETRACTABLE WINDOW GLASS AND VAN DOOR WINDOW GLASS INSTALLATION 1. 2. 3. Install seal (Figure 4, Item 5) on two glass panes (Figure 4, Item 6). Install glass unit (Figure 4, Item 4) with seal (Figure 4, Item 5) on window frame (Figure 4, Item 1). Install glass retainer (Figure 4, Item 2) on window frame (Figure 4, Item 1) with 18 screws (Figure 4, Item 3).
0605-6
TM 9-2320-272-23-4
0605
RETRACTABLE WINDOW GLASS AND VAN DOOR WINDOW GLASS INSTALLATION - Continued
1 2
4 6 5
M5313DAA
Window Glass Installation.
0605-7
TM 9-2320-272-23-4
0605
FOLLOW-ON MAINTENANCE 1. 2. Retract and secure van body (side door window only). (TM 9-2320-272-10) Install van rear door and side door window. (WP 0599)
0605-8
TM 9-2320-272-23-4
0606
FIELD MAINTENANCE VAN WINDOW SCREEN REPLACEMENT
0606-1
TM 9-2320-272-23-4
0606
REMOVAL Carefully remove screen retainer cord (Figure 1, Item 3) and screen (Figure 1, Item 2) from window frame (Figure 1, Item 1). END OF TASK INSTALLATION Position screen (Figure 1, Item 2) to window frame (Figure 1, Item 1) and install with screen retainer cord (Figure 1, Item 3).
1
M5316DAA
Window Screen Replacement.
0606-2
TM 9-2320-272-23-4
0607
FIELD MAINTENANCE VAN RETRACTABLE WINDOW REGULATOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin (Volume 5, WP 0827, Table 1, Item 341) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Van body fully expanded and secured (side door window only). (TM 9-2320-272-10)
0607-1
TM 9-2320-272-23-4
0607
REMOVAL 1. 2. 3. 4. Open retractable window (Figure 1, Item 2) and prop open. Remove cotter pin (Figure 1, Item 6) and regulator arm (Figure 1, Item 5) from frame bracket (Figure 1, Item 3). Discard cotter pin. Remove screw (Figure 1, Item 9) and crank handle (Figure 1, Item 8) from window regulator (Figure 1, Item 4). Remove three screws (Figure 1, Item 7) and window regulator (Figure 1, Item 4) from window frame (Figure 1, Item 1).
1 2
9 4 8 7 5 3
6
M5318DAA
Retractable Window Regulator Removal.
0607-2
TM 9-2320-272-23-4
0607
INSTALLATION 1. 2. 3. 4. Install window regulator (Figure 2, Item 4) on window frame (Figure 2, Item 1) with three screws (Figure 2, Item 7). Install crank handle (Figure 2, Item 8) on window regulator (Figure 2, Item 4) with screw (Figure 2, Item 9). Install regulator arm (Figure 2, Item 5) on frame bracket (Figure 2, Item 3) with cotter pin (Figure 2, Item 6). Close retractable window (Figure 2, Item 2).
1 2
9 4 8 7 5 3
6
M5319DAA
Retractable Window Regulator Installation.
Retract and secure van side panel (side door window only). (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0607-3/4 blank
TM 9-2320-272-23-4
0608
FIELD MAINTENANCE WINDOW REGULATOR AND INSIDE DOOR HANDLE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Cab door glass removed. (Volume 3, WP 0552)
0608-1
TM 9-2320-272-23-4
0608
REMOVAL 1. 2. 3. Remove screw (Figure 1, Item 7), window handle (Figure 1, Item 8), and washer (Figure 1, Item 9) from shaft (Figure 1, Item 10). Remove four screws (Figure 1, Item 1) and regulator (Figure 1, Item 6) from inner door panel (Figure 1, Item 2). Allow regulator arm stud (Figure 1, Item 3) to slide out of stationary track (Figure 1, Item 4) and remove through door inspection hole (Figure 1, Item 5).
2 3 4
9 7 8
6 10
5
M5217DAA
Window Removal.
0608-2
TM 9-2320-272-23-4
0608
INSTALLATION 1. 2. 3. Slide regulator arm stud (Figure 2, Item 3) into stationary track (Figure 2, Item 4) on regulator (Figure 2, Item 6). Install regulator (Figure 2, Item 6) on inner door (Figure 2, Item 2) with four screws (Figure 2, Item 1). Install washer (Figure 2, Item 9) and window handle (Figure 2, Item 8) on shaft (Figure 2, Item 10) with screw (Figure 2, Item 7).
2 3 4
9 7 8
6 10
5
M5218DAA
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE Install cab door glass. (Volume 3, WP 0552) END OF TASK END OF WORK PACKAGE
Window Installation.
0608-3/4 blank
TM 9-2320-272-23-4
0609
FIELD MAINTENANCE VAN SIDE PANEL-TO-ROOF TOGGLE CLAMP REPLACEMENT
0609-1
TM 9-2320-272-23-4
0609
REMOVAL 1. 2. Release toggle clamp (Figure 1, Item 5) and remove eyebolt (Figure 1, Item 3) from swivel hook (Figure 1, Item 2). Remove four screws (Figure 1, Item 4) and toggle clamp (Figure 1, Item 5) from hinged roof (Figure 1, Item 1).
1
M5325DAA
Figure 1. Side Panel-to-Roof Toggle Clamp Removal. END OF TASK
0609-2
TM 9-2320-272-23-4
0609
INSTALLATION 1. 2. Install toggle clamp (Figure 2, Item 5) on hinged roof (Figure 2, Item 1) with four screws (Figure 2, Item 4). Ensure eyebolt (Figure 2, Item 3) faces swivel hook (Figure 2, Item 2). Attach eyebolt (Figure 2, Item 3) of toggle clamp (Figure 2, Item 5) on swivel hook (Figure 2, Item 2) and close toggle clamp.
1
M5326DAA
Side Panel-to-Roof Toggle Clamp Installation.
0609-3/4 blank
TM 9-2320-272-23-4
0610
FIELD MAINTENANCE VAN TOGGLE CLAMP ANCHOR POST REPLACEMENT
0610-1
TM 9-2320-272-23-4
0610
REMOVAL Remove two screws (Figure 1, Item 3) and anchor post (Figure 1, Item 2) from hinged roof (Figure 1, Item 1). END OF TASK INSTALLATION Install anchor post (Figure 1, Item 2) on hinged roof (Figure 1, Item 1) with two screws (Figure 1, Item 3).
2 3
M5327DAA
Toggle Clamp Anchor Post Replacement.
0610-2
TM 9-2320-272-23-4
0611
FIELD MAINTENANCE VAN SIDE PANEL ROOF SWIVEL HOOK REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Van side panel fully expanded and secured (side door window only). (TM 9-2320-272-10)
0611-1
TM 9-2320-272-23-4
0611
REMOVAL 1. 2. Release toggle clamp (Figure 1, Item 5) and remove eyebolt (Figure 1, Item 4) from swivel hook (Figure 1, Item 2). Remove two screws (Figure 1, Item 1) and swivel hook (Figure 1, Item 2) from side panel (Figure 1, Item 3).
1
3
M5329DAA
Side Panel Roof Swivel Hook Removal.
0611-2
TM 9-2320-272-23-4
0611
INSTALLATION 1. 2. Install swivel hook (Figure 2, Item 2) on side panel (Figure 2, Item 3) with two screws (Figure 2, Item 1). Attach eyebolt (Figure 2, Item 4) of toggle clamp (Figure 2, Item 5) on swivel hook (Figure 2, Item 2) and close toggle clamp.
1
3
M5330DAA
Figure 2. Side Panel Roof Swivel Hook Installation. END OF TASK FOLLOW-ON MAINTENANCE Retract and secure van side panel (side door window only). (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0611-3/4 blank
TM 9-2320-272-23-4
0612
FIELD MAINTENANCE VAN LADDER LOCKING CLAMP REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Ladders removed. (TM 9-2320-272-10)
0612-1
TM 9-2320-272-23-4
0612
REMOVAL Remove four screws (Figure 1, Item 3) and locking clamp (Figure 1, Item 2) from door (Figure 1, Item 1).
3 2
M5331DAA
Ladder Locking Clamp Removal.
0612-2
TM 9-2320-272-23-4
0612
INSTALLATION Install locking clamp (Figure 2, Item 2) on door (Figure 2, Item 1) with four screws (Figure 2, Item 3).
3 2
M5332DAA
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE Install ladders. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
Ladder Locking Clamp Installation.
0612-3/4 blank
TM 9-2320-272-23-4
0613
FIELD MAINTENANCE VAN BONNET HANDLE AND CONTROL ROD REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin (Volume 5, WP 0827, Table 1, Item 341) Qty: 2 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Bonnet front door open and braced. (TM 9-2320-272-10)
0613-1
TM 9-2320-272-23-4
0613
REMOVAL 1. 2. Remove two cotter pins (Figure 1, Item 3) and control rod (Figure 1, Item 2) from handle (Figure 1, Item 5) and door bracket (Figure 1, Item 1). Discard cotter pins. Remove nut (Figure 1, Item 4), handle (Figure 1, Item 5), and spacer (Figure 1, Item 6) from handle mounting bracket (Figure 1, Item 7).
5 4 6 1 2 7
M5333DAA
Bonnet Handle and Control Rod Removal.
0613-2
TM 9-2320-272-23-4
0613
INSTALLATION 1. 2. Install spacer (Figure 2, Item 6) and handle (Figure 2, Item 5) on mounting bracket (Figure 2, Item 7) with nut (Figure 2, Item 4). Install control rod (Figure 2, Item 2) on door bracket (Figure 2, Item 1) and handle (Figure 2, Item 5) with two cotter pins (Figure 2, Item 3).
5 4 6 1 2 7
M5333DAA
Bonnet Handle and Control Rod Installation.
Close bonnet front door. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0613-3/4 blank
TM 9-2320-272-23-4
0614
FIELD MAINTENANCE VAN DOOR HINGE AND SEAL REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin (Volume 5, WP 0827, Table 1, Item 338) Qty: 1 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10)
0614-1
TM 9-2320-272-23-4
0614
REMOVAL 1. 2. Open door (Figure 1, Item 6). Remove cotter pin (Figure 1, Item 4), pin (Figure 1, Item 2), and door check arm (Figure 1, Item 3) from bracket (Figure 1, Item 1). Discard cotter pin.
NOTE
Assistant will help with Step (3). 3. 4. With the aid of an assistant, remove 15 screws (Figure 1, Item 5) and door (Figure 1, Item 6) from van body (Figure 1, Item 8). Remove 16 screws (Figure 1, Item 12), hinge seal retainer (Figure 1, Item 11), weather stripping (Figure 1, Item 9), hinge (Figure 1, Item 7), and outer hinge seal (Figure 1, Item 10) from door (Figure 1, Item 6).
0614-2
TM 9-2320-272-23-4
0614
REMOVAL - Continued
2 1 3
4 8
5 7 6
10 7 9
12 6
11
M5335DAA
Door Hinge and Seal Removal.
0614-3
TM 9-2320-272-23-4
0614
INSTALLATION 1. Install outer hinge seal (Figure 2, Item 10), hinge (Figure 2, Item 7), weather stripping (Figure 2, Item 9), and hinge seal retainer (Figure 2, Item 11) on door (Figure 2, Item 6) with 16 screws (Figure 2, Item 12).
NOTE
Assistant will help with Step (2). 2. 3. 4. With the aid of an assistant, install door (Figure 2, Item 6) on van body (Figure 2, Item 8) with 15 screws (Figure 2, Item 5). Install door check arm (Figure 2, Item 3) on bracket (Figure 2, Item 1) with pin (Figure 2, Item 2) and cotter pin (Figure 2, Item 4). Close door (Figure 2, Item 6).
0614-4
TM 9-2320-272-23-4
0614
2 1 3
4 8
5 7 6
10 7 9
12 6
11
M5336DAA
Door Hinge and Seal Installation.
0614-5/6 blank
TM 9-2320-272-23-4
0615
FIELD MAINTENANCE VAN PANEL SEALS REPLACEMENT
0615-1
TM 9-2320-272-23-4
0615
REMOVAL
NOTE
All panel seals are installed by retainers with either screws or screws and nuts. This procedure shows screws only. The quantity of screws may also differ. 1. 2. Raise panel seal (Figure 1, Item 4) to expose screws (Figure 1, Item 2). Remove screws (Figure 1, Item 2), as required, retainer (Figure 1, Item 3), and panel seal (Figure 1, Item 4) from van body (Figure 1, Item 1).
1
2 4 3
M5337DAA
Panel Seals Removal.
0615-2
TM 9-2320-272-23-4
0615
INSTALLATION 1. 2. Position retainer (Figure 2, Item 3) in flap of panel seal (Figure 2, Item 4) and align holes. Install panel seal (Figure 2, Item 4) and retainer (Figure 2, Item 3) on van body (Figure 2, Item 1) with screws (Figure 2, Item 2), as required.
1
2 4 3
M5338DAA
Panel Seals Installation.
0615-3/4 blank
TM 9-2320-272-23-4
0616
FIELD MAINTENANCE VAN DOOR HANDLE AND LOCK REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin (Volume 5, WP 0827, Table 1, Item 338) Qty: 2 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Rear doors open (rear door handle and lock replacement only). (TM 9-2320-272-10)
0616-1
TM 9-2320-272-23-4
0616
REMOVAL
NOTE
This procedure applies to van side and rear doors. 1. 2. 3. Remove pin (Figure 1, Item 10) and inner handle (Figure 1, Item 8) from handle shank (Figure 1, Item 9). Remove two cotter pins (Figure 1, Item 1), vertical bars (Figure 1, Item 2), and washers (Figure 1, Item 3) from lockpins (Figure 1, Item 4). Discard cotter pins. Remove four screws (Figure 1, Item 7) and door lock (Figure 1, Item 6) from door (Figure 1, Item 5).
10
3 7 6 2 5
M5339DAA
Door Handle and Lock Removal.
0616-2
TM 9-2320-272-23-4
0616
INSTALLATION 1. 2. 3. Install door lock (Figure 2, Item 6) on door (Figure 2, Item 5) with four screws (Figure 2, Item 7). Install two vertical bars (Figure 2, Item 2) on lockpins (Figure 2, Item 4) with two washers (Figure 2, Item 3) and cotter pins (Figure 2, Item 1). Install inner handle (Figure 2, Item 8) on handle shank (Figure 2, Item 9) with pin (Figure 2, Item 10).
10
3 7 6 2 5
M5340DAA
Door Handle and Lock Installation.
Close rear doors (rear door handle and lock replacement only). (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0616-3/4 blank
TM 9-2320-272-23-4
0617
FIELD MAINTENANCE VAN DOOR CHECKS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Lockwasher (Volume 5, WP 0827, Table 1, Item 403) Qty: 4 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Rear doors open. (TM 9-2320-272-10)
0617-1
TM 9-2320-272-23-4
0617
REMOVAL
NOTE
Blackout switch striker is removed with door check arm bracket on all doors except left rear. 1. Remove two screws (Figure 1, Item 9), lockwashers (Figure 1, Item 8), door check arm bracket (Figure 1, Item 12), and two washers (Figure 1, Item 2) from edge of door (Figure 1, Item 1) and blackout switch striker (Figure 1, Item 13). Discard lockwashers. Remove screw (Figure 1, Item 10), washer (Figure 1, Item 11), and blackout switch striker (Figure 1, Item 13) from edge of door (Figure 1, Item 1). Remove two nuts (Figure 1, Item 5), lockwashers (Figure 1, Item 6), screws (Figure 1, Item 3), and door check (Figure 1, Item 7) from bracket (Figure 1, Item 4). Discard lockwashers.
2. 3.
13 12 8 11 10 9
6 5
6 5
M5341DAA
Figure 1. Door Checks Removal. END OF TASK
0617-2
TM 9-2320-272-23-4
0617
INSTALLATION 1. 2. 3. Install door check (Figure 2, Item 7) on bracket (Figure 2, Item 4) with two screws (Figure 2, Item 3), lockwashers (Figure 2, Item 6), and nuts (Figure 2, Item 5). Install blackout switch striker (Figure 2, Item 13) on edge of door (Figure 2, Item 1) with washer (Figure 2, Item 11) and screw (Figure 2, Item 10). Install two washers (Figure 2, Item 2) and door check arm bracket (Figure 2, Item 12) on edge of door (Figure 2, Item 1) with two lockwashers (Figure 2, Item 8) and screws (Figure 2, Item 9).
13 12 8 11 10 9
6 5
6 5
M5342DAA
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE Close rear doors. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
Door Checks Installation.
0617-3/4 blank
TM 9-2320-272-23-4
0618
FIELD MAINTENANCE VAN LADDER RACK BUMPERS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Ladders removed. (TM 9-2320-272-10)
REMOVAL Remove two nuts (Figure 1, Item 3), screws (Figure 1, Item 1), washers (Figure 1, Item 4), and bumpers (Figure 1, Item 2) from ladder rack (Figure 1, Item 5). END OF TASK INSTALLATION Install two bumpers (Figure 1, Item 2) on ladder rack (Figure 1, Item 5) with two washers (Figure 1, Item 4), screws (Figure 1, Item 1), and nuts (Figure 1, Item 3).
4
Figure 1. END OF TASK FOLLOW-ON MAINTENANCE Install ladders. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
M5343DAA
Ladder Rack Bumpers Replacement.
0618-1/2 blank
TM 9-2320-272-23-4
0619
FIELD MAINTENANCE VAN SIDE PANEL RUBBER BUMPERS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Van side panel fully expanded and secured. (TM 9-2320-272-10)
REMOVAL
NOTE
Removal procedures for side panel bumpers, rubber bumpers (rear interior wall), and swivel hood rubber bumpers are the same. Remove screw (Figure 1, Item 2), washer (Figure 1, Item 3), and bumper (Figure 1, Item 4) from side panel (Figure 1, Item 1). END OF TASK INSTALLATION Install bumper (Figure 1, Item 4) on side panel (Figure 1, Item 1) with washer (Figure 1, Item 3) and screw (Figure 1, Item 2).
2
M5345DAA
Side Panel Rubber Bumper Replacement.
0619-1
TM 9-2320-272-23-4
0619
FOLLOW-ON MAINTENANCE Retract and secure van side panel. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0619-2
TM 9-2320-272-23-4
0620
FIELD MAINTENANCE VAN SIDE PANEL REAR LOCK REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin (Volume 5, WP 0827, Table 1, Item 338) Qty: 2 Lockwasher (Volume 5, WP 0827, Table 1, Item 215) Qty: 4 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Van side panel fully expanded and secured. (TM 9-2320-272-10)
0620-1
TM 9-2320-272-23-4
0620
REMOVAL 1. 2. 3. 4. 5. Remove eight screws (Figure 1, Item 5) and lock cover plate with insulation (Figure 1, Item 6) from side panel (Figure 1, Item 13). Remove two screws (Figure 1, Item 17) from lock bolt retainer (Figure 1, Item 16) and door frame (Figure 1, Item 18). Remove two cotter pins (Figure 1, Item 1), pins (Figure 1, Item 4), and clevises (Figure 1, Item 2) from locking arms (Figure 1, Item 3). Discard cotter pins. Remove nut (Figure 1, Item 7) and washer (Figure 1, Item 8) from lock (Figure 1, Item 11), and lock handle shank (Figure 1, Item 14). Remove four nuts (Figure 1, Item 9), lockwashers (Figure 1, Item 10), lock (Figure 1, Item 11), lockbolt (Figure 1, Item 12), and lock bolt retainer (Figure 1, Item 16) from side panel (Figure 1, Item 13), studs (Figure 1, Item 15), and door frame (Figure 1, Item 18). Discard lockwashers.
18 2 3 4 5
17
16 12 11 10
15
14
13
7 6
M5347DAA
Figure 1. END OF TASK INSTALLATION 1. 2. 3.
Side Panel Rear Lock Removal.
Position lock (Figure 2, Item 11) over lock handle shank (Figure 2, Item 14) and studs (Figure 2, Item 15). Slide lock bolt retainer (Figure 2, Item 16) over lockbolt (Figure 2, Item 12) and install on door frame (Figure 2, Item 18) with two screws (Figure 2, Item 17). Install lock (Figure 2, Item 11) on side panel (Figure 2, Item 13) and studs (Figure 2, Item 15) with four lockwashers (Figure 2, Item 10) and nuts (Figure 2, Item 9).
0620-2
TM 9-2320-272-23-4
0620
INSTALLATION - Continued 4. 5. 6. Install washer (Figure 2, Item 8) and nut (Figure 2, Item 7) on lock (Figure 2, Item 11) and lock handle shank (Figure 2, Item 14). Install two clevises (Figure 2, Item 2) on locking arms (Figure 2, Item 3) with two pins (Figure 2, Item 4) and cotter pins (Figure 2, Item 1). Install lock cover plate with insulation (Figure 2, Item 6) on side panel (Figure 2, Item 13) with eight screws (Figure 2, Item 5).
18 2 3 4 5
17
16 12 11 10
15
14
13
7 6
M5348DAA
Side Panel Rear Lock Installation.
Retract and secure van side panel. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0620-3/4 blank
TM 9-2320-272-23-4
0621
FIELD MAINTENANCE VAN SIDE PANEL FRONT LOCK AND HINGED-TYPE ROOF LOCK REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Grease, Automotive and Artillery (Volume 5, WP 0825, Table 1, Item 28) Cotter Pin Materials/Parts (cont.) (Volume 5, WP 0827, Table 1, Item 338) Qty: 2 Lockwasher (Volume 5, WP 0827, Table 1, Item 215) Qty: 4 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0621-1
TM 9-2320-272-23-4
0621
REMOVAL 1. 2. 3. 4. Remove eight screws (Figure 1, Item 11) and access plate (Figure 1, Item 12) from side panel (Figure 1, Item 2). Remove two cotter pins (Figure 1, Item 3), pins (Figure 1, Item 5), and clevises (Figure 1, Item 4) from lock arms (Figure 1, Item 6). Discard cotter pins. Remove nut (Figure 1, Item 8) and washer (Figure 1, Item 7) from lock (Figure 1, Item 6) and lock handle shank (Figure 1, Item 1). Remove four nuts (Figure 1, Item 9), lockwashers (Figure 1, Item 10), and lock (Figure 1, Item 6) from side panel (Figure 1, Item 2). Discard lockwashers.
0621-2
TM 9-2320-272-23-4
0621
REMOVAL - Continued
2 12 11
3 4 5 10 9 3
6 5 4
M9949DAA
Latch Assembly Removal.
0621-3
TM 9-2320-272-23-4
0621
INSTALLATION 1. 2. 3. 4. Position lock (Figure 2, Item 6) on side panel (Figure 2, Item 2) and lock handle shank (Figure 2, Item 1) and install washer (Figure 2, Item 7) and nut (Figure 2, Item 8). Install four lockwashers (Figure 2, Item 10) and nuts (Figure 2, Item 9) on lock (Figure 2, Item 6). Install two clevises (Figure 2, Item 4) on lock arms (Figure 2, Item 6) with two pins (Figure 2, Item 5) and cotter pins (Figure 2, Item 3). Install cover plate (Figure 2, Item 12) on side panel (Figure 2, Item 2) with eight screws (Figure 2, Item 11).
0621-4
TM 9-2320-272-23-4
0621
2 12 11
3 4 5 10 9 3
6 5 4
M9950DAA
Latch Assembly Installation.
0621-5/6 blank
TM 9-2320-272-23-4
0622
FIELD MAINTENANCE VAN SIDE PANEL EXTERIOR LOCK REPLACEMENT
REMOVAL 1. 2. Remove locking pin (Figure 1, Item 4) and release lock handle (Figure 1, Item 1). Remove four screws (Figure 1, Item 2) and lock (Figure 1, Item 3) from side panel (Figure 1, Item 5).
4 3 2 1
M5351DAA
Side Panel Exterior Lock Removal.
0622-1
TM 9-2320-272-23-4
0622
INSTALLATION 1. 2. Install lock (Figure 2, Item 3) on side panel (Figure 2, Item 5) with four screws (Figure 2, Item 2). Close lock handle (Figure 2, Item 1) and insert locking pin (Figure 2, Item 4).
4 3 2 1
M5352DAA
Side Panel Exterior Lock Installation.
0622-2
TM 9-2320-272-23-4
0623
FIELD MAINTENANCE VAN FLUORESCENT LIGHT TUBE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Fluorescent ceiling light switch off. (TM 9-2320-272-10)
0623-1
TM 9-2320-272-23-4
0623
REMOVAL 1. 2. Remove two screws (Figure 1, Item 2) and lower mesh guard (Figure 1, Item 4) from light fixture (Figure 1, Item 1). Remove three fluorescent tubes (Figure 1, Item 3) from light fixture (Figure 1, Item 1).
1
M5353DAA
Figure 1. Fluorescent Light Tube Removal. END OF TASK
0623-2
TM 9-2320-272-23-4
0623
INSTALLATION 1. 2. Install three fluorescent tubes (Figure 2, Item 3) on light fixture (Figure 2, Item 1). Position mesh guard (Figure 2, Item 4) on light fixture (Figure 2, Item 1) and install with two screws (Figure 2, Item 2).
1
M5354DAA
Fluorescent Light Tube Installation.
Check operation of fluorescent lights. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0623-3/4 blank
TM 9-2320-272-23-4
0624
FIELD MAINTENANCE VAN EMERGENCY/BLACKOUT LIGHT LAMP AND LENS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Emergency light switch off. (TM 9-2320-272-10) Blackout light switch off. (TM 9-2320-272-10)
REMOVAL
NOTE
Emergency light and blackout light lamps and lenses are replaced the same. This procedure is for the emergency light lamps and lenses. 1. 2. 3. Loosen lockscrew (Figure 1, Item 2) and open light door (Figure 1, Item 1). Remove lamp (Figure 1, Item 4) from lamp socket (Figure 1, Item 3). Turn lens retaining clip (Figure 1, Item 5) and remove lens (Figure 1, Item 6) from light door (Figure 1, Item 1).
1 1
6 5 2
4
M5355DAA
Figure 1. Emergency/Blackout Light Lamp and Lens Removal. END OF TASK
0624-1
TM 9-2320-272-23-4
0624
INSTALLATION
NOTE
White lens is installed in emergency light door and blue lens is installed in blackout light door. 1. 2. 3. Position lens (Figure 2, Item 6) in light door (Figure 2, Item 1) and install with lens retaining clip (Figure 2, Item 5). Install lamp (Figure 2, Item 4) in lamp socket (Figure 2, Item 3). Close light door (Figure 2, Item 1) and tighten lockscrew (Figure 2, Item 2).
1 1
6 5 2
4
M5356DAA
Figure 2. Emergency/Blackout Light Lamp and Lens Installation. END OF TASK FOLLOW-ON MAINTENANCE Check operation of emergency/blackout light. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0624-2
TM 9-2320-272-23-4
0625
FIELD MAINTENANCE VAN BLACKOUT LIGHT SWITCH AND 110-VOLT RECEPTACLE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Auxiliary A/C power source disconnected. (TM 9-2320-272-10)
0625-1
TM 9-2320-272-23-4
0625
REMOVAL 1. 2. 3. Remove three screws (Figure 1, Item 8) and cover plate (Figure 1, Item 7) from box (Figure 1, Item 2). Remove two screws (Figure 1, Item 9) and pull switch (Figure 1, Item 1) away from box (Figure 1, Item 2). Remove two screws (Figure 1, Item 6) and pull receptacle (Figure 1, Item 5) away from box (Figure 1, Item 2).
NOTE
Tag all leads for installation. 4. 5. Remove five screws (Figure 1, Item 4) and leads (Figure 1, Item 3) from pull switch (Figure 1, Item 1). Remove five screws (Figure 1, Item 4) and leads (Figure 1, Item 3) from receptacle (Figure 1, Item 5).
3 3 8 4 5 6 7
Figure 1. END OF TASK INSTALLATION 1. 2. 3. Install five leads (Figure 2, Item 3) on receptacle (Figure 2, Item 5) with five screws (Figure 2, Item 4). Install five leads (Figure 2, Item 3) on pull switch (Figure 2, Item 1) with five screws (Figure 2, Item 4). Install receptacle (Figure 2, Item 5) on box (Figure 2, Item 2) with two screws (Figure 2, Item 6). Blackout Light Switch and 110-Volt Receptacle Removal.
M9925DAA
0625-2
TM 9-2320-272-23-4
0625
INSTALLATION - Continued 4. 5. Install pull switch (Figure 2, Item 1) on box (Figure 2, Item 2) with two screws (Figure 2, Item 9). Install cover plate (Figure 2, Item 7) on box (Figure 2, Item 2) with three screws (Figure 2, Item 8).
3 3 8 4 5 6 7
Figure 2. Blackout Light Switch and 110-Volt Receptacle Installation. END OF TASK FOLLOW-ON MAINTENANCE Connect auxiliary A/C power source and check operation of light switch and 110-volt receptacle. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
M9926DAA
0625-3/4 blank
TM 9-2320-272-23-4
0626
FIELD MAINTENANCE VAN INSIDE TELEPHONE JACK POST REPLACEMENT
0626-1
TM 9-2320-272-23-4
0626
REMOVAL
NOTE
Inside telephone jack posts are located on van ceiling next to emergency light and on left rear panel below fire extinguisher. Both telephone jack posts are replaced the same. This procedure is for rear panel telephone jack post. 1. Remove four screws (Figure 1, Item 6) and pull junction box (Figure 1, Item 4) away from panel (Figure 1, Item 7).
NOTE
Ceiling telephone jack posts are connected with one wire. Tag all leads for installation. 2. 3. Remove screw (Figure 1, Item 1), two leads (Figure 1, Item 2), nut (Figure 1, Item 8), and telephone jack post (Figure 1, Item 5) from grommet (Figure 1, Item 3) and junction box (Figure 1, Item 4). Remove grommet (Figure 1, Item 3) from junction box (Figure 1, Item 4).
2 B 3 4 8 5 7 6
M9920DAA
Inside Telephone Jack Post Removal.
0626-2
TM 9-2320-272-23-4
0626
INSTALLATION 1. 2. 3. 4. Install grommet (Figure 2, Item 3) on junction box (Figure 2, Item 4). Install telephone jack post (Figure 2, Item 5) on grommet (Figure 2, Item 3) and junction box (Figure 2, Item 4) with nut (Figure 2, Item 8). Install two leads (Figure 2, Item 2) on telephone jack post (Figure 2, Item 5) with screw (Figure 2, Item 1). Install junction box (Figure 2, Item 4) on panel (Figure 2, Item 7) with four screws (Figure 2, Item 6).
2 B 3 4 8 5 7 6
M9921DAA
Inside Telephone Jack Post Installation.
0626-3/4 blank
TM 9-2320-272-23-4
0627
FIELD MAINTENANCE VAN OUTSIDE TELEPHONE JACK POST REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Gasket (Volume 5, WP 0827, Table 1, Item 202) Qty: 1 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Fire extinguisher removed. (TM 9-2320-272-10) Inside telephone jack posts removed. (WP 0626) Expand van. (TM 9-2320-272-10)
0627-1
TM 9-2320-272-23-4
0627
REMOVAL 1. 2. 3. 4. 5. Remove four screws (Figure 1, Item 16), cover (Figure 1, Item 17), and gasket (Figure 1, Item 15) from van body (Figure 1, Item 18). Discard gasket. Remove two screws (Figure 1, Item 5) and thermostat cover (Figure 1, Item 4) from two thermostats (Figure 1, Item 2) and inside panel (Figure 1, Item 19). Remove eight screws (Figure 1, Item 3) and two thermostats (Figure 1, Item 2) from inside panel (Figure 1, Item 19). Thermostats remain connected to wires. Remove 23 screws (Figure 1, Item 8) and panel retainer (Figure 1, Item 7) from inside panel (Figure 1, Item 19). Pry inside panel (Figure 1, Item 19) away from frame (Figure 1, Item 1) enough to clear studs (Figure 1, Item 6) and gain access to rear of junction box (Figure 1, Item 13).
NOTE
Tag all leads for installation. Assistant will help with Step (6). 6. 7. Remove screws (Figure 1, Item 9), lead (Figure 1, Item 10), nut (Figure 1, Item 11), and telephone jack post (Figure 1, Item 14) from grommet (Figure 1, Item 12) and junction box (Figure 1, Item 13). Remove grommet (Figure 1, Item 12) from junction box (Figure 1, Item 13).
0627-2
TM 9-2320-272-23-4
0627
REMOVAL - Continued
5
19
16 17 13
18
12 15 11 10
14 13
M9911DAA
Figure 1. Outside Telephone Jack Post Removal. END OF TASK 0627-3
TM 9-2320-272-23-4
0627
INSTALLATION 1. Install grommet (Figure 2, Item 12) on junction box (Figure 2, Item 13).
NOTE
Assistant will help with Step (2). 2. 3. 4. 5. 6. 7. 8. Install telephone jack post (Figure 2, Item 14) on grommet (Figure 2, Item 12) and junction box (Figure 2, Item 13). Install lead (Figure 2, Item 10) on telephone jack post (Figure 2, Item 14) with nut (Figure 2, Item 11) and screw (Figure 2, Item 9). Pry inside panel (Figure 2, Item 19) over studs (Figure 2, Item 6) and onto frame (Figure 2, Item 1). Install panel retainer (Figure 2, Item 7) on inside panel (Figure 2, Item 19) with 23 screws (Figure 2, Item 8). Install two thermostats (Figure 2, Item 2) on inside panel (Figure 2, Item 19) with eight screws (Figure 2, Item 3). Install thermostat cover (Figure 2, Item 4) on two thermostats (Figure 2, Item 2) and inside panel (Figure 2, Item 19) with two screws (Figure 2, Item 5). Install gasket (Figure 2, Item 15) and cover (Figure 2, Item 17) on van body (Figure 2, Item 18) with four screws (Figure 2, Item 16).
0627-4
TM 9-2320-272-23-4
0627
5
19
16 17 13
18
12 15 11 10
14 13
M9912DAA
Outside Telephone Jack Post Installation. 0627-5
TM 9-2320-272-23-4
0627
FOLLOW-ON MAINTENANCE 1. 2. Install inside panel telephone jack posts. (WP 0626) Install fire extinguisher. (TM 9-2320-272-10)
0627-6
TM 9-2320-272-23-4
0628
FIELD MAINTENANCE VAN SIDE AND REAR DOOR BLACKOUT LIGHT SWITCH REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Solder, Tin Alloy (Volume 5, WP 0825, Table 1, Item 64) Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Main power switch OFF. (TM 9-2320-272-10) Van side panel fully expanded and secured. (TM 9-2320-272-10)
REMOVAL 1. 2. 3. Remove two screws (Figure 1, Item 3) and blackout light switch (Figure 1, Item 2) from electrical panel (Figure 1, Item 7) or switch box (Figure 1, Item 1). Remove solder from terminals of blackout light switch (Figure 1, Item 2) and disconnect two wires (Figure 1, Item 6). Remove nut (Figure 1, Item 4) and plate (Figure 1, Item 5) from blackout light switch (Figure 1, Item 2).
1 7 2 2 3 3 4
6 5 6 5
4
M9922DAA
Side and Rear Door Blackout Light Switch Removal.
0628-1
TM 9-2320-272-23-4
0628
INSTALLATION 1. 2. 3. Connect two wires (Figure 2, Item 6) to terminals of blackout light switch (Figure 2, Item 2) and install with solder. Install door blackout light switch (Figure 2, Item 2) on electrical panel (Figure 2, Item 7) or switch box (Figure 2, Item 1) with two screws (Figure 2, Item 3). Install plate (Figure 2, Item 5) on blackout light switch (Figure 2, Item 2) with nut (Figure 3, Item 4).
1 7 2 2 3 3 4
6 5 6 5
4
M9923DAA
Figure 2. Side and Rear Door Blackout Light Switch Installation. END OF TASK ADJUSTMENT
NOTE
With main power switch, interior lights, and blackout light circuit on, interior lights must turn off when door starts to open, and turns on when door is closed. 1. 2. 3. Remove blackout light switch. See REMOVAL. Rotate ring (Figure 3, Item 2) down farther on threaded shaft of blackout light switch (Figure 3, Item 1). Install blackout light switch. See INSTALLATION.
0628-2
TM 9-2320-272-23-4
0628
ADJUSTMENT - Continued
1 2 2
M9924DAA
Figure 3. Side and Rear Door Blackout Light Adjustment. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Turn on main power switch and check operation of side and rear door blackout switches. (TM 9-2320-272-10) Retract and secure van body side panel. (TM 9-2320-272-10)
0628-3/4 blank
TM 9-2320-272-23-4
0629
FIELD MAINTENANCE VAN HINGED ROOF-OPERATED BLACKOUT CIRCUIT PLUNGERS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Main power switch off. (TM 9-2320-272-10) Van body side panel fully expanded and secured. (TM 9-2320-272-10)
0629-1
TM 9-2320-272-23-4
0629
REMOVAL 1. Remove four screws (Figure 1, Item 3) and pull plunger plate (Figure 1, Item 4) from hinged roof (Figure 1, Item 5).
NOTE
Tag all leads for installation. 2. Remove two screws (Figure 1, Item 1) and leads (Figure 1, Item 2) from plunger plate (Figure 1, Item 4).
0629-2
TM 9-2320-272-23-4
0629
REMOVAL - Continued
2 5
M9638DAA
Hinged Roof-Operated Blackout Circuit Plungers Removal.
0629-3
TM 9-2320-272-23-4
0629
INSTALLATION 1. 2. Install two leads (Figure 2, Item 2) on plunger plate (Figure 2, Item 4) with two screws (Figure 2, Item 1). Install plunger plate (Figure 2, Item 4) on hinged roof (Figure 2, Item 5) with four screws (Figure 2, Item 3).
2 5
M9639DAA
Figure 2. Hinged Roof-Operated Blackout Circuit Plungers Installation. END OF TASK
0629-4
TM 9-2320-272-23-4
0629
FOLLOW-ON MAINTENANCE 1. 2. Turn on main power switch and check operation of side and rear door blackout switches. (TM 9-2320-272-10) Retract and secure van body side panel. (TM 9-2320-272-10)
0629-5/6 blank
TM 9-2320-272-23-4
0630
FIELD MAINTENANCE VAN RETRACTABLE BEAM ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Grease, Automotive and Artillery (Volume 5, WP 0825, Table 1, Item 29, 30, 31, 32, 33) Cotter Pin (Volume 5, WP 0827, Table 1, Item 350) Qty: 4 Gasket (Volume 5, WP 0827, Table 1, Item 239) Qty: 1 Gasket (Volume 5, WP 0827, Table 1, Item 241) Qty: 1 Key (Volume 5, WP 0827, Table 1, Item 227) Qty: 5 Locknut (Volume 5, WP 0827, Table 1, Item 269) Qty: 1 Materials/Parts (cont.) Locknut (Volume 5, WP 0827, Table 1, Item 319) Qty: 2 Seal (Volume 5, WP 0827, Table 1, Item 240) Qty: 1 Personnel Required (2) References TM 9-237 Volume 5, WP 0819 Equipment Condition Parking brake set. (TM 9-2320-272-10) Van body sides fully expanded and secured. (TM 9-2320-272-10)
0630-1
TM 9-2320-272-23-4
0630
REMOVAL
NOTE
All support rollers are removed basically the same way. This procedure is for left-rear support rollers. 1. 2. Remove seven screws (Figure 1, Item 2), clamps (Figure 1, Item 3), and cover (Figure 1, Item 4) from underframe (Figure 1, Item 1). Remove two cotter pins (Figure 1, Item 5), support roller shaft (Figure 1, Item 7), and support roller (Figure 1, Item 6) from underframe (Figure 1, Item 1). Discard cotter pins.
1
2 4 3
5 5 7 6
M4011DAA
Figure 1. Retractable Beam Assembly Removal.
0630-2
TM 9-2320-272-23-4
0630
REMOVAL - Continued 3. Remove two cotter pins (Figure 2, Item 2), end roller shaft (Figure 2, Item 3), and end roller (Figure 2, Item 4) from underframe (Figure 2, Item 1). Discard cotter pins.
1 2
3 4
M4012DAA
Figure 2.
Retractable Beam Assembly Removal.
0630-3
TM 9-2320-272-23-4
0630
REMOVAL - Continued
NOTE
Left and right retractable beam drive shafts and locks are replaced the same. This procedure is for the left retractable beam drive shaft and lock. 4. 5. 6. 7. Remove locknut (Figure 3, Item 1) and lock (Figure 3, Item 2) from underframe stud (Figure 3, Item 8). Discard locknut. Remove screw (Figure 3, Item 4), pawl (Figure 3, Item 3), and lock (Figure 3, Item 2) from underframe (Figure 3, Item 5). Remove 30 screws (Figure 3, Item 7) and five covers (Figure 3, Item 6) from underframe (Figure 3, Item 5). Remove four setscrews (Figure 3, Item 15) from bushings (Figure 3, Item 14).
CAUTION
Do not bend or strain ratchet shaft during removal. Doing so may result in damage to equipment.
NOTE
Remove all nicks, burrs, and corrosion from ratchet shaft and lubricate before removal. Direct assistant to catch ratchet shaft components under van body during removal. 8. Slowly pull ratchet shaft (Figure 3, Item 9) and remove four bushings (Figure 3, Item 14), nine bushings (Figure 3, Item 13), spacers (Figure 3, Item 12), sprockets (Figure 3, Item 11), and five spacers (Figure 3, Item 10) from underframe (Figure 3, Item 5).
0630-4
TM 9-2320-272-23-4
0630
REMOVAL - Continued
1 2 3 4 5
8 6 7
15
14
13
12 11 10
M4013DAA
Figure 3.
0630-5
TM 9-2320-272-23-4
0630
REMOVAL - Continued
NOTE
All ten retractable beams are replaced the same way. This procedure is for the left-rear retractable beam. 9. Break welds between side panel (Figure 4, Item 1) and side panel support (Figure 4, Item 8) and remove retractable beam (Figure 4, Item 7) (TM 9-237).
CAUTION
Remove retractable beam slowly from underframe. Failure to do so may result in damage to equipment. 10. 11. Slide retractable beam (Figure 4, Item 7) under side panel (Figure 4, Item 1) and remove from underframe (Figure 4, Item 4) and channel (Figure 4, Item 5). Remove two locknuts (Figure 4, Item 13), washers (Figure 4, Item 12), screws (Figure 4, Item 9), seven screws (Figure 4, Item 10), retainer (Figure 4, Item 11), seal (Figure 4, Item 6), and gaskets (Figure 4, Items 2 and 3) from underframe (Figure 4, Item 4). Discard locknuts and seals.
0630-6
TM 9-2320-272-23-4
0630
REMOVAL - Continued
4 1 5 3
13 12 6
11 9 7 10
8
M4014DAA
0630-7
TM 9-2320-272-23-4
0630
CLEANING, INSPECTION, AND REPAIR 1. 2. 3. 4. 5. 6. 7. For General Cleaning Instructions, refer to (Volume 5, WP 0819). For General Inspection Instructions, refer to (Volume 5, WP 0819). Remove five keys (Figure 5, Item 2) and bushings (Figure 5, Item 1) from sprockets (Figure 5, Item 3). Discard keys. Inspect bushings (Figure 5, Items 1, 6, and 7) for wear and damage. If worn or damaged, replace bushings. Inspect ratchet shaft (Figure 5, Item 4) for burrs, nicks, and corrosion. If damaged, repair with file or emery cloth. If damage is excessive, replace. Test spring action of lock plunger (Figure 5, Item 5). If spring action is weak, replace lock. Install five keys (Figure 5, Item 2) and bushings (Figure 5, Item 1) on sprockets (Figure 5, Item 3).
0630-8
TM 9-2320-272-23-4
0630
CLEANING, INSPECTION, AND REPAIR - Continued
3 2 4
6 3
M4015DAA
Figure 5. Retractable Beam Assembly Cleaning, Inspection, and Repair. END OF TASK
0630-9
TM 9-2320-272-23-4
0630
INSTALLATION 1. Install seal (Figure 6, Item 6), gaskets (Figure 6, Items 2 and 3), and retainer (Figure 6, Item 11) on underframe (Figure 6, Item 4) with seven screws (Figure 6, Item 10), two screws (Figure 6, Item 9), washers (Figure 6, Item 12), and locknuts (Figure 6, Item 13).
CAUTION
Install retractable beam slowly into underframe. Failure to do so may result in damage to equipment. 2. 3. Slide retractable beam (Figure 6, Item 7) under side panel (Figure 6, Item 1) and install in underframe (Figure 6, Item 4) at channel (Figure 6, Item 5). Install retractable beam (Figure 6, Item 7) by welding retractable beam (Figure 6, Item 7) to side panel (Figure 6, Item 1) and side panel support (Figure 6, Item 8) (TM 9-237).
0630-10
TM 9-2320-272-23-4
0630
3 1 2
4 5
12
13 6
11 9 7 10
8
M4016DAA
Figure 6. Retractable Beam Assembly Installation.
0630-11
TM 9-2320-272-23-4
0630
CAUTION
Do not bend or strain ratchet shaft during installation. Doing so may result in damage to equipment.
NOTE
Bevel forward end of ratchet shaft for installation. Apply GAA grease on two feet (61 cm) of forward end of ratchet shaft for installation. Direct assistant to install ratchet shaft components under van body when installing ratchet shaft. 4. Slowly insert ratchet shaft (Figure 7, Item 2) into underframe (Figure 7, Item 1) and install five spacers (Figure 7, Item 3), sprockets (Figure 7, Item 11), spacers (Figure 7, Item 12), nine bushings (Figure 7, Item 13), and four bushings (Figure 7, Item 15). Install four setscrews (Figure 7, Item 16) in bushings (Figure 7, Item 15) in underframe channels (Figure 7, Item 14). Lubricate ratchet shaft (Figure 7, Item 2) with GAA grease (TM 9-2320-272-10). Install five covers (Figure 7, Item 7) on underframe (Figure 7, Item 1) with 30 screws (Figure 7, Item 8). Install lock (Figure 7, Item 4) and pawl (Figure 7, Item 5) on underframe stud (Figure 7, Item 9) and underframe (Figure 7, Item 1) with locknut (Figure 7, Item 10) and screw (Figure 7, Item 6).
5. 6. 7. 8.
0630-12
TM 9-2320-272-23-4
0630
1 2
16 15 14 13 12 11 3
10 4 9 5 6 1
7 8
M4017DAA
0630-13
TM 9-2320-272-23-4
0630
INSTALLATION - Continued 9. Install end roller (Figure 8, Item 4) on underframe (Figure 8, Item 1) with end roller shaft (Figure 8, Item 3) and two cotter pins (Figure 8, Item 2).
1 2
3 4
M4018DAA
NOTE
All support rollers are installed basically the same way. This procedure is for left-rear support rollers. 10. 11. Install support roller (Figure 9, Item 5) on underframe (Figure 9, Item 1) with support roller shaft (Figure 9, Item 6) and two cotter pins (Figure 9, Item 4). Install cover (Figure 9, Item 7) on underframe (Figure 9, Item 1) with seven clamps (Figure 9, Item 3) and screws (Figure 9, Item 2).
0630-14
TM 9-2320-272-23-4
0630
1
2 7 3
4 4 6 5
M4019DAA
Figure 9. Retractable Beam Assembly Installation. END OF TASK FOLLOW-ON MAINTENANCE Retract van body sides. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0630-15/16 blank
TM 9-2320-272-23-4
0631
FIELD MAINTENANCE VAN HEATER AND EXHAUST REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Tape, Antiseizing (Volume 5, WP Lockwasher (Volume 5, WP Qty: 4 Lockwasher (Volume 5, WP Qty: 7 Lockwasher (Volume 5, WP Qty: 1 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Battery ground cables disconnected. (Volume 2, WP 0350)
0825, Table 1, Item 65) 0827, Table 1, Item 301)
0827, Table 1, Item 403)
0827, Table 1, Item 424)
0631-1
TM 9-2320-272-23-4
0631
REMOVAL 1. 2. Remove eight screws (Figure 1, Item 25), exhaust pipe (Figure 1, Item 26), and two clamps (Figure 1, Item 22) from van body (Figure 1, Item 1) and heater exhaust pipe (Figure 1, Item 19). Remove two screws (Figure 1, Item 21), lockwashers (Figure 1, Item 23), nuts (Figure 1, Item 24), and clamps (Figure 1, Item 22) from exhaust pipe (Figure 1, Item 26). Discard lockwashers.
NOTE
Tag all leads and lines for installation. 3. 4. 5. 6. 7. 8. 9. Remove nut (Figure 1, Item 8) and fuel overflow line (Figure 1, Item 12) from fitting (Figure 1, Item 7). Remove nut (Figure 1, Item 13) and fuel receptacle line (Figure 1, Item 14) from heater fuel valve (Figure 1, Item 6). Disconnect power receptacle connector (Figure 1, Item 17) from heater (Figure 1, Item 2). Disconnect external fuel pump receptacle connector (Figure 1, Item 15) from heater (Figure 1, Item 2). Disconnect room thermostat connector (Figure 1, Item 16) from heater (Figure 1, Item 2). Remove four screws (Figure 1, Item 3) and lockwashers (Figure 1, Item 4) from heater bracket (Figure 1, Item 5). Discard lockwashers. Remove screw (Figure 1, Item 11), ground strap (Figure 1, Item 10), and lockwasher (Figure 1, Item 9) from bracket (Figure 1, Item 5) and heater (Figure 1, Item 2). Discard lockwasher.
NOTE
Assistant will help with Step (10). 10. 11. 12. 13. Remove heater (Figure 1, Item 2) from van body (Figure 1, Item 1). Remove five screws (Figure 1, Item 11) and lockwashers (Figure 1, Item 9) from two brackets (Figure 1, Item 5) and heater (Figure 1, Item 2). Discard lockwashers. Remove heater exhaust pipe (Figure 1, Item 19) from heater (Figure 1, Item 2). Remove four screws (Figure 1, Items 27 and 20) and two seals (Figure 1, Item 18) from van body (Figure 1, Item 1).
0631-2
TM 9-2320-272-23-4
0631
REMOVAL - Continued
1 2 25 24 23 27 3 25 26
24 23 22 21 20 18 19 18 5
VIEW ROTATED 180 17 2
16 15
14 13 6 7 3 4 5 12 11
M9013DAA
8 9 10
Van Heater and Exhaust Removal.
0631-3
TM 9-2320-272-23-4
0631
INSTALLATION 1. 2. 3. 4. Apply antiseizing tape to male threads of heater fuel valve (Figure 2, Item 6) and heater nipple (Figure 2, Item 7). Install two seals (Figure 2, Item18) on van body (Figure 2, Item 1) with eight screws (Figure 2, Item 5). Install two brackets (Figure 2, Item 5) on heater (Figure 2, Item 2) with five screws (Figure 2, Item 11) and lockwashers (Figure 2, Item 9). Install heater exhaust pipe (Figure 2, Item 19) on heater (Figure 2, Item 2).
NOTE
Assistant will help with Step (5). 5. 6. 7. 8. 9. 10. 11. 12. 13. Place heater (Figure 2, Item 2) in van body (Figure 2, Item 1). Install bracket (Figure 2, Item 5) on van body (Figure 2, Item 1) with four screws (Figure 2, Item 3) and lockwashers (Figure 2, Item 4). Install ground strap (Figure 2, Item 10) on bracket (Figure 2, Item 5) and heater (Figure 2, Item 2) with screws (Figure 2, Item 11) and lockwasher (Figure 2, Item 9). Install fuel overflow line (Figure 2, Item 12) on fitting (Figure 2, Item 7) with nut (Figure 2, Item 8). Install fuel receptacle line (Figure 2, Item 14) on heater fuel valve (Figure 2, Item 6) with nut (Figure 2, Item 13). Connect external fuel pump receptacle connector (Figure 2, Item 15) to heater (Figure 2, Item 2). Connect power receptacle connector (Figure 2, Item 17) to heater (Figure 2, Item 2). Connect room thermostat connector (Figure 2, Item 16) to heater (Figure 2, Item 2). Install exhaust pipe (Figure 2, Item 26) on heater exhaust pipe (Figure 2, Item 19) with two clamps (Figure 2, Item 22), eight screws (Figure 2, Item 25), two screws (Figure 2, Item 21), lockwashers (Figure 2, Item 23), and nuts (Figure 2, Item 24).
0631-4
TM 9-2320-272-23-4
0631
1 2 25 24 23 27 3 25 26
24 23 22 21 20 18 19 18 5
VIEW ROTATED 180 17 2
16 15
14 13 6 7 3 4 5 12 11
M9014DAA
8 9 10
Van Heater and Exhaust Installation.
0631-5
TM 9-2320-272-23-4
0631
FOLLOW-ON MAINTENANCE Connect battery ground cables. (Volume 2, WP 0350) END OF TASK END OF WORK PACKAGE
0631-6
TM 9-2320-272-23-4
0632
FIELD MAINTENANCE VAN HEATER FUEL PUMP REPLACEMENT (M934/A1/A2)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Tape, Antiseizing (Volume 5, WP 0825, Table 1, Item 65) Locknut (Volume 5, WP 0827, Table 1, Item 285) Qty: 2 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Battery ground cables disconnected. (Volume 2, WP 0350)
0632-1
TM 9-2320-272-23-4
0632
REMOVAL (M934A1/A2) 1. 2. 3. 4. 5. Loosen two locking studs (Figure 1, Item 8) from turnbuckles (Figure 1, Item 3) and open access door (Figure 1, Item 9). Disconnect fuel pump lead (Figure 1, Item 10) from harness lead (Figure 1, Item 11). Disconnect output line (Figure 1, Item 4) from elbow (Figure 1, Item 5). Disconnect input line (Figure 1, Item 1) from elbow (Figure 1, Item 2). Remove two locknuts (Figure 1, Item 12), screws (Figure 1, Item 6), clamp (Figure 1, Item 7) with fuel pump lead (Figure 1, Item 10), and fuel pump (Figure 1, Item 14) from hinge plate (Figure 1, Item 13). Discard locknuts. Remove elbows (Figure 1, Item 2) and (Figure 1, Item 5) from fuel pump (Figure 1, Item 14).
6.
0632-2
TM 9-2320-272-23-4
0632
REMOVAL (M934A1/A2) - Continued
1 2 3 3 4
14
13 12
11
10
9
M9914DAA
Figure 1. Van Heater Fuel Pump Removal (M934A1/A2). END OF TASK
0632-3
TM 9-2320-272-23-4
0632
INSTALLATION (M934A1/A2)
NOTE
Wrap male threads with antiseize tape prior to installation. 1. 2. 3. 4. 5. 6. Install elbows (Figure 2, Item 2) and (Figure 2, Item 5) on fuel pump (Figure 2, Item 14). Install fuel pump (Figure 2, Item 14) and clamp (Figure 2, Item 7) with fuel pump lead (Figure 2, Item 10) on hinge plate (Figure 2, Item 13) with two screws (Figure 2, Item 6) and locknuts (Figure 2, Item 12). Connect input line (Figure 2, Item 1) to elbow (Figure 2, Item 2). Connect output line (Figure 2, Item 4) to elbow (Figure 2, Item 5). Connect fuel pump lead (Figure 2, Item 10) to harness lead (Figure 2, Item 11). Close access door (Figure 2, Item 9) and tighten two locking studs (Figure 2, Item 8) in turnbuckles (Figure 2, Item 3).
0632-4
TM 9-2320-272-23-4
0632
INSTALLATION (M934A1/A2) - Continued
1 2 3 3 4
14
13 12
11
10
9
M9915DAA
Van Heater Fuel Pump Installation (M934A1/A2).
0632-5
TM 9-2320-272-23-4
0632
REMOVAL (M934)
WARNING
Diesel fuel is highly flammable. Do not perform fuel system procedures near open flame. Failure to comply may result in injury or death to personnel. 1. 2. 3. 4. 5. 6. Remove seven screws (Figure 3, Item 13) and cover (Figure 3, Item 12) from van body (Figure 3, Item 5). Disconnect fuel pump lead (Figure 3, Item 11) from harness lead (Figure 3, Item 10). Remove outlet line (Figure 3, Item 3) and bushing (Figure 3, Item 2) from elbow (Figure 3, Item 1). Disconnect inlet line (Figure 3, Item 9) from adapter (Figure 3, Item 8). Remove two screws (Figure 3, Item 7), clamp (Figure 3, Item 14), and fuel pump (Figure 3, Item 4) from van body (Figure 3, Item 5). Remove elbow (Figure 3, Item 1), adapter (Figure 3, Item 8), and elbow (Figure 3, Item 6) from fuel pump (Figure 3, Item 4).
0632-6
TM 9-2320-272-23-4
0632
REMOVAL (M934) - Continued
2 3
13 14
6 5 8 9 7
11 12
10
M9916DAA
Van Heater Fuel Pump Removal (M934).
0632-7
TM 9-2320-272-23-4
0632
INSTALLATION (M934)
NOTE
Wrap male threads with antiseize tape prior to installation. 1. 2. 3. 4. 5. 6. Install elbow (Figure 4, Item 6), adapter (Figure 4, Item 8), and elbow (Figure 4, Item 1) on fuel pump (Figure 4, Item 4). Install fuel pump (Figure 4, Item 4) and clamp (Figure 4, Item 14) on van body (Figure 4, Item 5) with two screws (Figure 4, Item 7). Connect inlet line (Figure 4, Item 9) on adapter (Figure 4, Item 8). Install bushing (Figure 4, Item 2) and outlet line (Figure 4, Item 3) on elbow (Figure 4, Item 1). Connect fuel pump lead (Figure 4, Item 11) to harness lead (Figure 4, Item 10). Install cover (Figure 4, Item 12) on van body (Figure 4, Item 5) with seven screws (Figure 4, Item 13).
2 3
13 14
6 5 8 9 7
11 12 10
M9917DAA
Figure 4. Van Heater Fuel Pump Installation (M934). END OF TASK
0632-8
TM 9-2320-272-23-4
0632
0632-9/10 blank
TM 9-2320-272-23-4
0633
FIELD MAINTENANCE AIR CONDITIONER DRAIN TUBE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Adhesive, Silicone Rubber (Volume 5, WP 0825, Table 1, Item 3) Tape, Antiseizing (Volume 5, WP 0825, Table 1, Item 65) Cotter Pin Materials/Parts (cont.) (Volume 5, WP 0827, Table 1, Item 341) Qty: 1 Sleeve (Volume 5, WP 0827, Table 1, Item 259) Qty: 1 References TM 9-243 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0633-1
TM 9-2320-272-23-4
0633
REMOVAL 1. 2. 3. 4. 5. 6. 7. Open bonnet door (Figure 1, Item 5) and support with support rod (Figure 1, Item 6). Remove cotter pin (Figure 1, Item 13) and door rod (Figure 1, Item 2) from bonnet (Figure 1, Item 1). Discard cotter pin. Remove drain tube (Figure 1, Item 7) and sleeve (Figure 1, Item 4) from elbow (Figure 1, Item 3). Discard sleeve. Remove four screws (Figure 1, Item 11), clamps (Figure 1, Item 12), and drain tube (Figure 1, Item 7) from van body (Figure 1, Item 10). Remove drain tube (Figure 1, Item 7) from two grommets (Figure 1, Item 8) and bonnet (Figure 1, Item 1). Remove two grommets (Figure 1, Item 8) from bonnet holes (Figure 1, Item 9). Remove elbow (Figure 1, Item 3) from air conditioner (Figure 1, Item 14).
0633-2
TM 9-2320-272-23-4
0633
REMOVAL - Continued
1 2 3 4
6 7 8
9 14 13 11 10 12 8
11
12
M10133DAA
Air Conditioner Drain Tube Removal.
0633-3
TM 9-2320-272-23-4
0633
INSTALLATION
NOTE
Wrap male threads with antiseize tape prior to installation. 1. 2. Install elbow (Figure 2, Item 3) on air conditioner (Figure 2, Item 14). Install two grommets (Figure 2, Item 8) in bonnet holes (Figure 2, Item 9).
CAUTION
Do not crimp drain tube when routing through bonnet holes; drainage will stop.
NOTE
If tube was damaged, refer to TM 9-243 for tube fabrication. 3. 4. 5. 6. 7. Insert drain tube (Figure 2, Item 7) through grommets (Figure 2, Item 8). Install sleeve (Figure 2, Item 4) and drain tube (Figure 2, Item 7) on elbow (Figure 2, Item 3). Install drain tube (Figure 2, Item 7) on van body (Figure 2, Item 10) with four clamps (Figure 2, Item 12) and screws (Figure 2, Item 11). Release bonnet (Figure 2, Item 1) door (Figure 2, Item 5) support rod (Figure 2, Item 6). Install door rod (Figure 2, Item 2) on bonnet door (Figure 2, Item 5) with cotter pin (Figure 2, Item 13).
0633-4
TM 9-2320-272-23-4
0633
1 2 3 4
6 7 8
9 14 13 11 10 12 8
11
12
M10134DAA
Air Conditioner Drain Tube Installation.
0633-5/6 blank
TM 9-2320-272-23-4
0634
FIELD MAINTENANCE HEATER FUEL PUMP WIRING HARNESS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Battery ground cables disconnected. (Volume 2, WP 0350)
REMOVAL
NOTE
Perform Step (1) on M934 vehicles only. Tag wires for installation. 1. 2. Remove screw (Figure 1, Item 1) and clamp (Figure 1, Item 4) from fuel pump wiring harness (Figure 1, Item 3). Disconnect wiring harness (Figure 1, Item 3) from fuel pump connector plug (Figure 1, Item 2).
3 M934
2
M3049DAA
Figure 1. Heater Fuel Pump Wiring Harness Removal.
0634-1
TM 9-2320-272-23-4
0634
REMOVAL - Continued 3. 4. Disconnect wiring harness (Figure 2, Item 1) from heater (Figure 2, Item 2). Remove wiring harness (Figure 2, Item 1) from van body (Figure 2, Item 3).
M3050DAA
Figure 2. Heater Fuel Pump Wiring Harness Removal. END OF TASK
0634-2
TM 9-2320-272-23-4
0634
INSTALLATION 1. 2. Position wiring harness (Figure 3, Item 1) on van body (Figure 3, Item 3). Connect wiring harness (Figure 3, Item 1) to heater (Figure 3, Item 2).
3
Figure 3.
M9918DAA
Heater Fuel Pump Wiring Harness Installation.
0634-3
TM 9-2320-272-23-4
0634
INSTALLATION - Continued 3. Connect wiring harness (Figure 4, Item 3) to fuel pump connector plug (Figure 4, Item 2).
NOTE
Perform Step (4) on M934 vehicles only. 4. Install clamp (Figure 4, Item 4) on wiring harness (Figure 4, Item 3) with screw (Figure 4, Item 1).
3 M934
2
M9919DAA
Heater Fuel Pump Wiring Harness Installation.
Connect battery ground cables. (Volume 2, WP 0350) END OF TASK END OF WORK PACKAGE
0634-4
TM 9-2320-272-23-4
0635
FIELD MAINTENANCE RIGHT AND LEFT SIDE BLACKOUT HARNESS REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) References TM 9-2320-272-24P Volume 3, WP 0352 Equipment Condition Parking brake set. (TM 9-2320-273-10) Equipment Condition (cont.) Van body sides fully extended and secured. (TM 9-2320-272-10) Hinged roof-operated blackout circuit plungers removed. (WP 0629)
0635-1
TM 9-2320-272-23-4
0635
REMOVAL
NOTE
Tag wires for installation. 1. 2. 3. 4. Remove six screws (Figure 1, Item 21) and cover (Figure 1, Item 20) from load center (Figure 1, Item 15). Remove screw (Figure 1, Item 14) and wire (Figure 1, Item 13) from neutral buss bar (Figure 1, Item 16). Remove screw (Figure 1, Item 10) and wire (Figure 1, Item 11) from relay (Figure 1, Item 12). Remove two screws (Figure 1, Items 5 and 9) and wires (Figure 1, Item 7 and 8) from rear door blackout switch (Figure 1, Item 6).
NOTE
Perform Steps (5) through (8) for left and right side of van body. 5. 6. 7. 8. 9. Remove six screws (Figure 1, Item 24) and cover (Figure 1, Item 22) from van body (Figure 1, Item 26). Remove grommet (Figure 1, Item 4) from van body (Figure 1, Item 26). Remove grommet (Figure 1, Item 19), two screws (Figure 1, Item 17), and connector halves (Figure 1, Item 18) from harness (Figure 1, Item 23) and cover (Figure 1, Item 22). Remove grommet (Figure 1, Item 3), two screws (Figure 1, Item 25), and connector halves (Figure 1, Item 1) from harness (Figure 1, Item 23) and ceiling truss (Figure 1, Item 2). Pull harness (Figure 1, Item 23) through hole in ceiling truss (Figure 1, Item 2) and remove harness (Figure 1, Item 23) from load center (Figure 1, Item 15).
0635-2
TM 9-2320-272-23-4
0635
REMOVAL - Continued
1 26
5 6 7 8 9
25 24 23 22 18 21
10 11 12 13
20 19
Figure 1. END OF TASK REPAIR For van wiring harness repair (Volume 3, WP 0352). END OF TASK
14 17
Blackout Harness.
16
15
M3051DAA
0635-3
TM 9-2320-272-23-4
0635
INSTALLATION 1. Push harness (Figure 2, Item 23) through hole in ceiling truss (Figure 2, Item 2) and position harness (Figure 2, Item 23) on load center (Figure 2, Item 15).
NOTE
Perform Steps (2) through (5) for left and right side of van body. 2. 3. 4. 5. 6. 7. 8. 9. Install two connector halves (Figure 2, Item 1) on harness (Figure 2, Item 23) and ceiling truss (Figure 2, Item 2) with two screws (Figure 2, Item 25) and grommet (Figure 2, Item 3). Install cover (Figure 2, Item 22) on van body (Figure 2, Item 26) with six screws (Figure 2, Item 24). Install two connector halves (Figure 2, Item 18) on harness (Figure 2, Item 23) and cover (Figure 2, Item 22) with two screws (Figure 2, Item 17) and grommet (Figure 2, Item 19). Install grommet (Figure 2, Item 4) on van body (Figure 2, Item 26). Install wires (Figure 2, Item 7 and 8) on rear door blackout switch (Figure 2, Item 6) with screws (Figure 2, Items 5 and 9). Install wire (Figure 2, Item 11) on relay (Figure 2, Item 12) with screw (Figure 2, Item 10). Install wire (Figure 2, Item 13) on neutral buss bar (Figure 2, Item 16) with screw (Figure 2, Item 14). Install cover (Figure 2, Item 20) on load center (Figure 2, Item 15) with six screws (Figure 2, Item 21).
1 26
5 6 7 8 9
25 24 23 22 18 21
10 11 12 13
20 19
14 17
Blackout Harness.
16
15
M3052DAA
0635-4
TM 9-2320-272-23-4
0635
FOLLOW-ON MAINTENANCE 1. 2. Install hinged roof-operated blackout circuit plungers. (WP 0629) Retract van body sides. (TM 9-2320-272-10)
0635-5/6 blank
TM 9-2320-272-23-4
0636
FIELD MAINTENANCE CIRCUIT BREAKER HARNESS AND CIRCUIT BREAKER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 285) Qty: 2 Lockwasher (Volume 5, WP 0827, Table 1, Item 407) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Battery ground cables disconnected. (Volume 2, WP 0350)
0636-1
TM 9-2320-272-23-4
0636
REMOVAL
NOTE
Tag wires for installation. 1. 2. 3. 4. Disconnect wire (Figure 1, Item 3) from circuit breaker (Figure 1, Item 2). Remove two screws (Figure 1, Item 4) and clamps (Figure 1, Item 1) from wiring harness (Figure 1, Item 15) and van body (Figure 1, Item 16). Remove locknut (Figure 1, Item 10), screw (Figure 1, Item 13), and clamp (Figure 1, Item 14) from spare tire carrier mounting bracket (Figure 1, Item 5). Discard locknut. Remove locknut (Figure 1, Item 6), screw (Figure 1, Item 12), washer (Figure 1, Item 11), wires (Figure 1, Items 8 and 9), and lockwasher (Figure 1, Item 7) from spare tire carrier mounting bracket (Figure 1, Item 5). Discard locknut and lockwasher. Remove wiring harness (Figure 1, Item 15) from van body (Figure 1, Item 16). Disconnect emergency lamp wiring harness (Figure 1, Item 18) from circuit breaker (Figure 1, Item 2). Remove two screws (Figure 1, Item 17) and circuit breaker (Figure 1, Item 2) from van body (Figure 1, Item 16).
5. 6. 7.
0636-2
TM 9-2320-272-23-4
0636
REMOVAL - Continued
1 2 1 3 4 5
6 16 15 4 13 12 11 10 16 14 7 8 9
17
18
2
M3053DAA
Circuit Breaker Harness and Circuit Breaker Removal.
0636-3
TM 9-2320-272-23-4
0636
INSTALLATION 1. 2. 3. 4. 5. 6. Install circuit breaker (Figure 2, Item 2) on van body (Figure 2, Item 16) with two screws (Figure 2, Item 17). Connect emergency lamp wiring harness (Figure 2, Item 18) to circuit breaker (Figure 2, Item 2). Install lockwasher (Figure 2, Item 7) and wires (Figure 2, Items 8 and 9) on spare tire carrier mounting bracket (Figure 2, Item 5) with washer (Figure 2, Item 11), screw (Figure 2, Item 12), and locknut (Figure 2, Item 6). Install wiring harness (Figure 2, Item 15) on spare tire carrier mounting bracket (Figure 2, Item 5) with screw (Figure 2, Item 8), clamp (Figure 2, Item 14), and locknut (Figure 2, Item 10). Install two clamps (Figure 2, Item 1) and wiring harness (Figure 2, Item 15) and van body (Figure 2, Item 16) with two screws (Figure 2, Item 4). Connect wire (Figure 2, Item 3) to circuit breaker (Figure 2, Item 2).
0636-4
TM 9-2320-272-23-4
0636
1 2 1 3 4 5
6 16 15 4 13 12 11 10 16 14 7 8 9
17
18
2
M3054DAA
Circuit Breaker Harness and Circuit Breaker Installation.
0636-5
TM 9-2320-272-23-4
0636
0636-6
TM 9-2320-272-23-4
0637
FIELD MAINTENANCE ENTRANCE RECEPTACLE 220V 3-PHASE WIRING HARNESS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Wire, Nonelectrical (Volume 5, WP 0825, Table 1, Item 70) Locknut (Volume 5, WP 0827, Table 1, Item 314) Qty: 4 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) External power source removed. (TM 9-2320-272-10) Battery ground cables disconnected. (Volume 2, WP 0350)
0637-1
TM 9-2320-272-23-4
0637
REMOVAL
NOTE
Tag wires for installation. 1. 2. 3. 4. 5. 6. Remove six screws (Figure 1, Item 14) and cover (Figure 1, Item 17) from load center (Figure 1, Item 4). Remove three screws (Figure 1, Item 15) and wires (Figure 1, Item 16) from circuit breakers (Figure 1, Item 5). Remove setscrew (Figure 1, Item 2) and wire (Figure 1, Item 1) from neutral buss bar (Figure 1, Item 3). Remove three screws (Figure 1, Item 7) and plate (Figure 1, Item 6) from electrical box (Figure 1, Item 12). Remove four locknuts (Figure 1, Item 13), screws (Figure 1, Item 8), and receptacle (Figure 1, Item 9) from van body (Figure 1, Item 11). Discard locknuts. Disconnect connector (Figure 1, Item 10) from receptacle (Figure 1, Item 9).
NOTE
Safety wire will be used to route wires through van body. 7. Remove wires (Figure 1, Items 1 and 16) from electrical box (Figure 1, Item 12), load center (Figure 1, Item 4), and van body (Figure 1, Item 11).
0637-2
TM 9-2320-272-23-4
0637
REMOVAL - Continued
3 17 1
2 16
15 6
14
13 12 7
11 8
10 9
Figure 1. END OF TASK Entrance Receptacle Removal.
M3055DAA
0637-3
TM 9-2320-272-23-4
0637
INSTALLATION
NOTE
Safety wire will be used to route wires through van body. 1. 2. 3. 4. 5. 6. 7. Feed wires (Figure 2, Items 1 and 16) through electrical box (Figure 2, Item 12), load center (Figure 2, Item 4), and van body (Figure 2, Item 11). Connect connector (Figure 2, Item 10) to receptacle (Figure 2, Item 9). Install receptacle (Figure 2, Item 9) on van body (Figure 2, Item 11) with four screws (Figure 2, Item 8) and locknuts (Figure 2, Item 13). Install plate (Figure 2, Item 6) on electrical box (Figure 2, Item 12) with three screws (Figure 2, Item 7). Install wire (Figure 2, Item 1) on neutral buss bar (Figure 2, Item 3) with setscrew (Figure 2, Item 2). Install three wires (Figure 2, Item 16) on circuit breakers (Figure 2, Item 5) with three screws (Figure 2, Item 15). Install cover (Figure 2, Item 17) on load center (Figure 2, Item 4) with six screws (Figure 2, Item 14).
0637-4
TM 9-2320-272-23-4
0637
3 17 1
2 16
15 6
14
13 12 7
11 8
10 9
Figure 2. END OF TASK Entrance Receptacle Installation.
M3056DAA
0637-5
TM 9-2320-272-23-4
0637
FOLLOW-ON MAINTENANCE 1. 2. Connect battery ground cables. (Volume 2, WP 0350) Install external power source. (TM 9-2320-272-10)
0637-6
TM 9-2320-272-23-4
0638
FIELD MAINTENANCE FLEXIBLE CONVERTER WIRING HARNESS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Gasket (Volume 5, WP 0827, Table 1, Item 30) Qty: 1 Lockwasher (Volume 5, WP 0827, Table 1, Item 255) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0638-1
TM 9-2320-272-23-4
0638
REMOVAL
NOTE
Tag wires for installation. 1. 2. 3. 4. Remove connector (Figure 1, Item 8) from junction box (Figure 1, Item 9). Remove four screws (Figure 1, Item 10), cover (Figure 1, Item 11), and gasket (Figure 1, Item 1) from converter (Figure 1, Item 3). Remove three nuts (Figure 1, Item 5), wires (Figure 1, Item 6), and lockwasher (Figure 1, Item 4) from converter (Figure 1, Item 3). Remove wiring harness (Figure 1, Item 7) from van body (Figure 1, Item 2).
1 11 2
3 10
9 8
6 6 7
M3057DAA
Figure 1. Flexible Converter Wiring Harness Removal. END OF TASK
0638-2
TM 9-2320-272-23-4
0638
INSTALLATION 1. 2. 3. 4. Install wiring harness (Figure 2, Item 7) on van body (Figure 2, Item 2). Install three wires (Figure 2, Item 6) and lockwasher (Figure 2, Item 4) on converter (Figure 2, Item 3) with three nuts (Figure 2, Item 5). Install gasket (Figure 2, Item 1) and cover (Figure 2, Item 11) on converter (Figure 2, Item 3) with four screws (Figure 2, Item 10). Install connector (Figure 2, Item 8) on junction box (Figure 2, Item 9).
1 11 2
3 10
9 8
6 6 7
M3058DAA
Flexible Converter Wiring Harness Installation.
0638-3/4 blank
TM 9-2320-272-23-4
0639
FIELD MAINTENANCE ELECTRICAL LOAD CENTER BOX REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Sealing Compound (Volume 5, WP 0825, Table 1, Item 57) Lockwasher (Volume 5, WP 0827, Table 1, Item 382) Qty: 3 References TM 9-237 Equipment Condition Parking brake set. (TM 9-2320-272-10) Battery ground cables disconnected. (Volume 2, WP 0350) External power source disconnected. (TM 9-2320-272-10)
0639-1
TM 9-2320-272-23-4
0639
REMOVAL
NOTE
Tag wires for installation. 1. 2. 3. 4. 5. 6. Remove six screws (Figure 1, Item 19) and cover (Figure 1, Item 20) from load center (Figure 1, Item 4). Remove three screws (Figure 1, Item 17) and wires (Figure 1, Item 21) from relay (Figure 1, Item 3). Remove screw (Figure 1, Item 11) and wire (Figure 1, Item 16) from neutral buss bar (Figure 1, Item 5). Remove screws (Figure 1, Items 10 and 11) and two wires (Figure 1, Items 13 and 14) from circuit breakers (Figure 1, Items 6 and 7). Remove screw (Figure , Item 9) and wire (Figure 1, Item 12) from circuit breaker (Figure 1, Item 8). Remove screw (Figure 1, Item 1), clamp (Figure 1, Item 2), and right main wiring harness (Figure 1, Item 18) from load center (Figure 1, Item 4).
1 21 20 19
2 3 4 5 6
18 16 15 14 13
17
7 8
12 11 10 9
M10286DAA
Figure 1.
Load Center Box.
0639-2
TM 9-2320-272-23-4
0639
REMOVAL - Continued 7. 8. 9. 10. 11. 12. Remove three screws (Figure 2, Item 16) and wires (Figure 2, Item 1) from relay (Figure 2, Item 2). Remove screw (Figure 2, Item 14) and wire (Figure 2, Item 15) from neutral buss bar (Figure 2, Item 4). Remove screw (Figure 2, Item 10) and wires (Figure 2, Item 13) from circuit breaker (Figure 2, Item 5). Remove screw (Figure 2, Item 9) and wires (Figure 2, Item 12) from circuit breaker (Figure 2, Item 6). Remove screw (Figure 2, Item 8) and wire (Figure 2, Item 11) from circuit breaker (Figure 2, Item 7). Remove left main wiring harness (Figure 2, Item 17) from load center (Figure 2, Item 3).
1 2 3 17 16 15 14 13 12 11 10 4 5 6 7
9 8
M3059DAA
Figure 2.
Load Center Box.
0639-3
TM 9-2320-272-23-4
0639
REMOVAL - Continued 13. 14. 15. Remove screw (Figure 3, Item 8) and wires (Figure 3, Item 7 and 9) from relay (Figure 3, Item 2). Remove screw (Figure 3, Item 5) and wire (Figure 3, Item 6) from circuit breaker (Figure 3, Item 4). Remove blackout bypass wiring harness (Figure 3, Item 1) from load center (Figure 3, Item 3).
9 8
2 3
7 6 5
Figure 3. Load Center Box.
M10287DAA
0639-4
TM 9-2320-272-23-4
0639
REMOVAL - Continued 16. Remove nut (Figure 4, Item 1), screw (Figure 4, Item 5), two washers (Figure 4, Items 4 and 12), cable assembly (Figure 4, Item 3), ground cable (Figure 4, Item 2), and cable (Figure 4, Item 11) from load center (Figure 4, Item 6). Remove three screws (Figure 4, Item 8) and wires (Figure 4, Item 9) from three circuit breakers (Figure 4, Item 7). Remove air conditioner wiring harness (Figure 4, Item 10) from load center (Figure 4, Item 6).
17. 18.
2 1 12 11 3 4
6 10
9 7 8
M3060DAA
Figure 4.
Load Center Box.
0639-5
TM 9-2320-272-23-4
0639
REMOVAL - Continued 19. 20. 21. Remove screw (Figure 5, Item 8) and wire (Figure 5, Item 7) from neutral buss bar (Figure 5, Item 3). Remove three screws (Figure 5, Item 5) and wires (Figure 5, Item 6) from three circuit breakers (Figure 5, Item 4). Remove right 10 kW electric heater wiring harness (Figure 5, Item 1) from load center (Figure 5, Item 2).
3 8 7 4 6 5
M10288DAA
Figure 5.
Load Center Box.
0639-6
TM 9-2320-272-23-4
0639
REMOVAL - Continued 22. 23. 24. Remove screw (Figure 6, Item 8) and wire (Figure 6, Item 7) from neutral buss bar (Figure 6, Item 3). Remove screw (Figure 6, Item 5) and wire (Figure 6, Item 6) from circuit breaker (Figure 6, Item 4). Remove right electric heater wiring harness (Figure 6, Item 1) from load center (Figure 6, Item 2).
4 7 6 5
M10289DAA
Figure 6.
Load Center Box.
0639-7
TM 9-2320-272-23-4
0639
REMOVAL - Continued 25. 26. 27. Disconnect cables (Figure 7, Items 3 and 4) from connectors (Figure 7, Item 2 and 6). Remove eight screws (Figure 7, Item 5) and cover (Figure 7, Item 7) from junction box (Figure 7, Item 8). Remove wires (Figure 7, Items 1 and 9) from connectors (Figure 7, Items 2 and 6).
9 8 2 1 3 4
M3061DAA
Figure 7.
Load Center Box.
0639-8
TM 9-2320-272-23-4
0639
REMOVAL - Continued 28. 29. Remove five screws (Figure 8, Item 4) and wires (Figure 8, Item 5) from five circuit breakers (Figure 8, Item 3). Remove converter wiring harness (Figure 8, Item 1) from load center (Figure 8, Item 2).
1 2
3 5
M10290DAA
Figure 8.
Load Center Box.
0639-9
TM 9-2320-272-23-4
0639
REMOVAL - Continued 30. 31. 32. Remove screw (Figure 9, Item 7) and wire (Figure 9, Item 1) from neutral buss bar (Figure 9, Item 2). Remove three screws (Figure 9, Item 5) and wires (Figure 9, Item 6) from three circuit breakers (Figure 9, Item 4). Remove wire (Figure 9, Item 8) and entrance receptacle wiring harness (Figure 9, Item 1) from load center (Figure 9, Item 3).
M3062DAA
Figure 9.
Load Center Box.
0639-10
TM 9-2320-272-23-4
0639
REMOVAL - Continued 33. 34. 35. 36. Remove screw (Figure 10, Item 13) and wire (Figure 10, Item 12) from relay (Figure 10, Item 11). Remove two screws (Figure 10, Item 4) and wires (Figure 10, Item 5 and 7) from switch (Figure 10, Item 6). Remove screw (Figure 10, Item 10) and wire (Figure 10, Item 8) from neutral buss bar (Figure 10, Item 9). Remove right and left blackout wiring harnesses (Figure 10, Item 1 and 2) from load center (Figure 10, Item 3).
1 2 3 13 4 12 5 6 7 11 4 8 9 10
M10291DAA
Figure 10.
Load Center Box.
0639-11
TM 9-2320-272-23-4
0639
REMOVAL - Continued 37. 38. 39. Remove screw (Figure 11, Item 8) and wire (Figure 11, Item 2) from neutral buss bar (Figure 11, Item 3). Remove three screws (Figure 11, Item 6) and wires (Figure 11, Item 7) from three circuit breakers (Figure 11, Item 5). Remove right 3-phase receptacle wiring harness (Figure 11, Item 1) from load center (Figure 11, Item 4).
2 1 3 8 4
7 6
M10292DAA
Figure 11.
Load Center Box.
0639-12
TM 9-2320-272-23-4
0639
REMOVAL - Continued 40. 41. 42. Remove screw (Figure 12, Item 7) and wire (Figure 12, Item 1) from neutral buss bar (Figure 12, Item 2). Remove three screws (Figure 12, Item 5) and wires (Figure 12, Item 6) from three circuit breakers (Figure 12, Item 4). Remove left 3-phase receptacle wiring harness (Figure 12, Item 8) from load center (Figure 12, Item 3).
1 8 2
7 3
6 5
M10293DAA
Figure 12.
Load Center Box.
0639-13
TM 9-2320-272-23-4
0639
REMOVAL - Continued 43. 44. 45. Remove four screws (Figure 13, Item 6) and washers (Figure 13, Item 1) from load center (Figure 13, Item 2). Remove special nut (Figure 13, Item 5) from conduit nut (Figure 13, Item 4). Remove load center (Figure 13, Item 2) from van body (Figure 13, Item 3).
0639-14
TM 9-2320-272-23-4
0639
REMOVAL - Continued
1 6 2
5
M3063DAA
Load Center Box.
0639-15
TM 9-2320-272-23-4
0639
DISASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Remove six plates (Figure 14, Item 33) from load center cover (Figure 14, Item 34). Remove two screws (Figure 14, Item 29), jumper wire (Figure 14, Item 30), and ground B cable (Figure 14, Item 32) from relay (Figure 14, Item 2). Remove screws (Figure 14, Items 25 and 28) and ground N cable (Figure 14, Item 31) from relay (Figure 14, Item 2) and neutral buss bar (Figure 14, Item 9). Remove screw (Figure 14, Item 26) and ground B cable (Figure 14, Item 32) from neutral buss bar (Figure 14, Item 9). Remove screws (Figure 14, Items 3 and 23) and relay cable (Figure 14, Item 1) from 20-amp circuit breaker (Figure 14, Item 24) and relay (Figure 14, Item 2). Remove three screws (Figure 14, Item 4), lockwashers (Figure 14, Item 5), and relay (Figure 14, Item 2) from load center box (Figure 14, Item 10). Discard lockwashers. Remove screw (Figure 14, Item 19) and cable (Figure 14, Item 6) from neutral buss bar (Figure 14, Item 9). Remove six screws (Figure 14, Item 25) and insulators (Figure 14, Item 13) from load center (Figure 14, Item 10). Remove nine screws (Figure 14, Item 22) and nine 20-amp circuit breakers (Figure 14, Item 24) from load center (Figure 14, Item 10). Remove three screws (Figure 14, Item 20) and 30-amp circuit breaker (Figure 14, Item 21) from load center (Figure 14, Item 10). Remove three screws (Figure 14, Item 18) and 40-amp circuit breaker (Figure 14, Item 19) from load center (Figure 14, Item 10). Remove 12 screws (Figure 14, Item 17) and four 20-amp circuit breakers (Figure 14, Item 12) from load center (Figure 14, Item 10). Remove three screws (Figure 14, Item 16) and 100-amp circuit breaker (Figure 14, Item 15) from load center (Figure 14, Item 10). Remove grommet (Figure 14, Item 11) from load center (Figure 14, Item 10). Remove two screws (Figure 14, Item 8) and blackout door switch (Figure 14, Item 7) from load center (Figure 14, Item 10).
0639-16
TM 9-2320-272-23-4
0639
34 6 7
3 2 4
8 1 33 25 29 30 31 13 14 24 23 22 21 33 20 19 14 18 17 16 15 10 11
M3064DAA
26
27 32
28
13
12
Load Center Box.
0639-17
TM 9-2320-272-23-4
0639
ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Install 100-amp circuit breaker (Figure 15, Item 15) on load center (Figure 15, Item 10) with three screws (Figure 15, Item 16). Install four 20-amp circuit breakers (Figure 15, Item 12) on load center (Figure 15, Item 10) with 12 screws (Figure 15, Item 17). Install 40-amp circuit breaker (Figure 15, Item 19) on load center (Figure 15, Item 10) with three screws (Figure 15, Item 18). Install 30-amp circuit breaker (Figure 15, Item 21) on load center (Figure 15, Item 10) with three screws (Figure 15, Item 20). Install nine 20-amp circuit breakers (Figure 15, Item 24) on load center (Figure 15, Item 10) with nine screws (Figure 15, Item 22). Install six insulators (Figure 15, Item 13) on load center (Figure 15, Item 10) with six screws (Figure 7, Item 8). Install relay (Figure 15, Item 2) on load center (Figure 15, Item 10) with three lockwashers (Figure 15, Item 5) and screws (Figure 15, Item 4). Install cable (Figure 15, Item 6) on neutral buss bar (Figure 15, Item 9) with screw (Figure 15, Item 26). Install relay cable (Figure 15, Item 1) on 20-amp circuit breaker (Figure 15, Item 24) and relay (Figure 15, Item 2) with two screws (Figure 15, Items 11 and 33). Install ground B cable (Figure 15, Item 32) on neutral buss bar (Figure 15, Item 9) with screw (Figure 15, Item 26). Install ground N cable (Figure 15, Item 31) on relay (Figure 15, Item 2) and neutral buss bar (Figure 15, Item 9) with two screws (Figure 15, Items 25 and 28). Install jumper wire (Figure 15, Item 30) and ground B cable (Figure 15, Item 32) on relay (Figure 15, Item 2) with two screws (Figure 15, Item 29). Install six plates (Figure 15, Item 33) on load center cover (Figure 15, Item 34). Install blackout door switch (Figure 15, Item 7) on load center (Figure 15, Item 10) with two screws (Figure 15, Item 8). Install grommet (Figure 15, Item 11) on load center (Figure 15, Item 10).
0639-18
TM 9-2320-272-23-4
0639
34
3 2 4
8 1 33 25 29 30 31 13 14 24 23 22 21 33 20 19 14 18 17 16 15
Figure 15. END OF TASK Load Center Box.
26
27 32
28
13
12
10 11
M3065DAA
0639-19
TM 9-2320-272-23-4
0639
INSTALLATION 1. Install load center (Figure 16, Item 2) on van body (Figure 16, Item 3) and conduit (Figure 16, Item 4) with four washers (Figure 16, Item 1), screws (Figure 16, Item 6), and special nut (Figure 16, Item 5).
1 6 2
5
M10294DAA
Figure 16.
Load Center Box.
0639-20
TM 9-2320-272-23-4
0639
INSTALLATION - Continued 2. Install left 3-phase receptacle wiring harness (Figure 17, Item 8) and three wires (Figure 17, Item 6) in load center (Figure 17, Item 3) and on triple circuit breaker (Figure 17, Item 4) with three screws (Figure 17, Item 5). Install wire (Figure 17, Item 1) on neutral buss bar (Figure 17, Item 2) with screw (Figure 17, Item 7).
3.
1 8 2
7 3
6 5
M3066DAA
Figure 17.
Load Center Box.
0639-21
TM 9-2320-272-23-4
0639
INSTALLATION - Continued 4. Install right 3-phase receptacle wiring harness (Figure 18, Item 8) and three wires (Figure 18, Item 6) in load center (Figure 18, Item 3) and on three circuit breakers (Figure 18, Item 4) with three screws (Figure 18, Item 5). Install wire (Figure 18, Item 1) on neutral buss bar (Figure 18, Item 2) with screw (Figure 18, Item 7).
5.
1 8 2 7 3
6 5
M10295DAA
Figure 18.
Load Center Box.
0639-22
TM 9-2320-272-23-4
0639
INSTALLATION - Continued 6. 7. 8. Install right and left wiring harnesses (Figure 19, Items 1 and 2) and wire (Figure 19, Item 19) in load center (Figure 19, Item 3) and on neutral buss bar (Figure 19, Item 10) with screw (Figure 19, Item 11). Install two wires (Figure 19, Items 5 and 7) on switch (Figure 19, Item 6) with screws (Figure 19, Items 4 and 8). Install wire (Figure 19, Item 13) on relay (Figure 19, Item 12) with screw (Figure 19, Item 14).
1 2 3 14 4 13 5 6 7 14 8 9 10 11
M3067DAA
Figure 19.
Load Center Box.
0639-23
TM 9-2320-272-23-4
0639
INSTALLATION - Continued 9. 10. Install three wires (Figure 20, Item 6) and entrance receptacle harness (Figure 20, Item 8) on circuit breakers (Figure 20, Item 4) in load center (Figure 20, Item 3) with three screws (Figure 20, Item 5). Install wire (Figure 20, Item 1) on neutral buss bar (Figure 20, Item 2) with screw (Figure 20, Item 7).
M10296DAA
Figure 20.
Load Center Box.
0639-24
TM 9-2320-272-23-4
0639
INSTALLATION - Continued 11. Install five wires (Figure 21, Item 6) and converter wiring harness (Figure 21, Item 7) on circuit breakers (Figure 21, Item 3) in load center (Figure 21, Item 2) with five screws (Figure 21, Item 5). Route auxiliary pump wiring harness (Figure 21, Item 1) through coupling (Figure 21, Item 4).
1 2
3 6
5 4
Figure 21.
M3068DAA
Load Center Box.
0639-25
TM 9-2320-272-23-4
0639
INSTALLATION - Continued 12. Install wires (Figure 22, Items 1 and 9) on connectors (Figure 22, Items 2 and 6) (TM 9-237).
NOTE
Apply sealing compound before performing Step (13). 13. 14. Install cover (Figure 22, Item 7) on junction box (Figure 22, Item 8) with eight screws (Figure 22, Item 5). Connect cables (Figure 22, Items 3 and 4) to connectors (Figure 22, Items 2 and 6).
9 8 2 1 3 4
M10297DAA
Figure 22.
Load Center Box.
0639-26
TM 9-2320-272-23-4
0639
INSTALLATION - Continued 15. Install wires (Figure 23, Items 6 and 7) and right 10 kW electric heater wiring harness (Figure 23, Item 1) on circuit breaker (Figure 23, Item 3) in load center (Figure 23, Item 4) and neutral buss bar (Figure 23, Item 2) with screws (Figure 23, Items 5 and 8).
4 7 6 5
M10298DAA
Figure 23.
Load Center Box.
0639-27
TM 9-2320-272-23-4
0639
INSTALLATION - Continued 16. Install wire (Figure 24, Item 6), three wires (Figure 24, Item 5), and left electric heater wiring harness (Figure 24, Item 1) on neutral buss bar (Figure 24, Item 2) and circuit breakers (Figure 24, Item 3) with screw (Figure 24, Item 7) and three screws (Figure 24, Item 4).
2 7 6 3 5 4
Figure 24.
M3069DAA
Load Center Box.
0639-28
TM 9-2320-272-23-4
0639
INSTALLATION - Continued 17. 18. Install three wires (Figure 25, Item 9) and air conditioner wiring harness (Figure 25, Item 10) in load center (Figure 25, Item 6) and on circuit breaker (Figure 25, Item 7) with three screws (Figure 25, Item 8). Install cable assembly (Figure 25, Item 3), ground cable (Figure 25, Item 2), and cable (Figure 25, Item 9) on load center (Figure 25, Item 6) with screw (Figure 25, Item 5), washers (Figure 25, Items 4 and 12), and nut (Figure 25, Item 1).
2 1 12 11 3 4
6 10
9 7 8
M10299DAA
Figure 25.
Load Center Box.
0639-29
TM 9-2320-272-23-4
0639
INSTALLATION - Continued 19. Install wires (Figure 26, Items 6, 7, and 9), and blackout bypass wiring harness (Figure 26, Item 1) in load center (Figure 26, Item 3) and on relay (Figure 26, Item 2) and circuit breaker (Figure 26, Item 4) with two screws (Figure 26, Item 8) and screw (Figure 26, Item 5).
9 8
2 3
7 6 5
M3070DAA
Figure 26.
Load Center Box.
0639-30
TM 9-2320-272-23-4
0639
INSTALLATION - Continued 20. 21. 22. 23. 24. 25. Position left main wiring harness (Figure 27, Item 1) on load center (Figure 27, Item 3). Install two wires (Figure 27, Item 13) on circuit breaker (Figure 27, Item 5) with screw (Figure 27, Item 10). Install two wires (Figure 27, Item 12) on circuit breaker (Figure 27, Item 6) with screw (Figure 27, Item 9). Install wire (Figure 27, Item 11) on circuit breaker (Figure 27, Item 7) with screw (Figure 27, Item 8). Install wire (Figure 27, Item 15) on neutral buss bar (Figure 27, Item 4) with screw (Figure 27, Item 14). Install three wires (Figure 27, Item 17) on relay (Figure 27, Item 2) with three screws (Figure 27, Item 16).
1 17 2 3 4 16 15 14 13 12 11 10 7 5 6
9 8
M10300DAA
Figure 27.
Load Center Box.
0639-31
TM 9-2320-272-23-4
0639
INSTALLATION - Continued 26. Install two wires (Figure 28, Items 13 and 14), wire (Figure 28, Item 12), right main wiring harness (Figure 28, Item 18), clamp (Figure 28, Item 2), and screw (Figure 28, Item 1) in load center (Figure 28, Item 4) and on three circuit breakers (Figure 28, Items 6, 7, and 8) with three screws (Figure 28, Items 9, 10, and 11). Install wire (Figure 28, Item 16) on neutral buss bar (Figure 28, Item 5) with screw (Figure 28, Item 15). Install three wires (Figure 28, Item 21) on relay (Figure 28, Item 3) with three screws (Figure 28, Item 17). Install cover (Figure 28, Item 20) on load center (Figure 28, Item 4) with six screws (Figure 28, Item 19).
27. 28. 29.
1 21 20 19
2 3 4 5 6
18 16 15 14 13
17
7 8
12 11 10 9
M3071DAA
Load Center Box.
Connect battery ground cables. (Volume 2, WP 0350) Connect external power source. (TM 9-2320-272-10)
0639-32
TM 9-2320-272-23-4
0640
FIELD MAINTENANCE ELECTRICAL BOX REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Battery ground cables disconnected. (Volume 2, WP 0350) Entrance receptacle 220V 3-phase harness removed. (WP 0637)
0640-1
TM 9-2320-272-23-4
0640
REMOVAL 1. 2. 3. 4. Remove electrical box (Figure 1, Item 5) from van body end panel (Figure 1, Item 2). Remove six screws (Figure 1, Item 7) and bracket (Figure 1, Item 1) from electrical box (Figure 1, Item 5). Remove grommet (Figure 1, Item 6) from electrical box (Figure 1, Item 5). Remove screw (Figure 1, Item 3) and plate (Figure 1, Item 4) from electrical box (Figure 1, Item 5).
1 7
3 4
M3072DAA
Figure 1. Electrical Box Removal. END OF TASK
0640-2
TM 9-2320-272-23-4
0640
INSPECTION Inspect all parts for damage. Replace damaged parts. END OF TASK INSTALLATION 1. 2. 3. 4. Install plate (Figure 2, Item 4) on electrical box (Figure 2, Item 5) with screw (Figure 2, Item 3). Install grommet (Figure 2, Item 6) on electrical box (Figure 2, Item 5). Install bracket (Figure 2, Item 1) on electrical box (Figure 2, Item 5) with six screws (Figure 2, Item 7). Position electrical box (Figure 2, Item 5) on van body end panel (Figure 2, Item 2).
1 7
3 4
M3073DAA
Electrical Box Installation.
0640-3
TM 9-2320-272-23-4
0640
FOLLOW-ON MAINTENANCE 1. 2. Install entrance receptacle 220V 3-phase harness. (WP 0637) Connect battery ground cables. (Volume 2, WP 0350)
0640-4
TM 9-2320-272-23-4
0641
FIELD MAINTENANCE ELECTRICAL JUNCTION BOX REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Sealing Compound (Volume 5, WP 0825, Table 1, Item 60) Locknut (Volume 5, WP 0827, Table 1, Item 321) Qty: 8 References TM 9-237 Equipment Condition Parking brake set. (TM 9-2320-272-10) Battery ground cables disconnected. (Volume 2, WP 0350)
0641-1
TM 9-2320-272-23-4
0641
REMOVAL 1. 2. Remove two cables (Figure 1, Item 5) from connectors (Figure 1, Item 3). Remove eight screws (Figure 1, Item 6) and cover (Figure 1, Item 7) from junction box (Figure 1, Item 9).
NOTE
Tag wires for installation. 3. 4. Remove harness leads (Figure 1, Items 1 and 8) from two connectors (Figure 1, Item 3) (TM 9-237). Remove eight locknuts (Figure 1, Item 2), screws (Figure 1, Item 4), and two connectors (Figure 1, Item 3) from cover (Figure 1, Item 7). Discard locknuts.
3 4 5
2 1
9 8
6
M10280DAA
Figure 1.
Electrical Junction Box Removal.
0641-2
TM 9-2320-272-23-4
0641
REMOVAL - Continued 5. 6. Remove special nut (Figure 2, Item 7), nut (Figure 2, Item 9), adapter (Figure 2, Item 6), and nut (Figure 2, Item 5) from junction box (Figure 2, Item 8). Remove junction box (Figure 2, Item 8) from conduits (Figure 2, Items 2 and 4) and slide off wires (Figure 2, Items 1 and 3).
2 1 3
7 6 5
M3074DAA
Electrical Junction Box Removal.
0641-3
TM 9-2320-272-23-4
0641
INSTALLATION 1. 2. 3. 4. 5. 6. Place nut (Figure 3, Item 9) on conduit (Figure 3, Item 2). Feed harness leads (Figure 3, Items 1 and 3) through holes in junction box (Figure 3, Item 8). Position junction box (Figure 3, Item 8) on conduits (Figure 3, Items 2 and 4). Install nut (Figure 3, Item 9) on junction box (Figure 3, Item 8). Feed conduit (Figure 3, Item 4) through nut (Figure 3, Item 5), adapter (Figure 3, Item 6), junction box (Figure 3, Item 8), and special nut (Figure 3, Item 7). Install special nut (Figure 3, Item 7) on junction box (Figure 3, Item 8).
2 1 3
7 6
Figure 3.
M3075DAA
Electrical Junction Box Installation.
0641-4
TM 9-2320-272-23-4
0641
INSTALLATION - Continued 7. 8. 9. 10. Install two connectors (Figure 4, Item 3) on cover (Figure 4, Item 7) with eight screws (Figure 4, Item 4) and locknuts (Figure 4, Item 2). Connect harness leads (Figure 4, Items 1 and 8) to two connectors (Figure 4, Item 3) (TM 9-237). Coat edge of cover (Figure 4, Item 7) with sealing compound and install cover (Figure 4, Item 7) on junction box (Figure 4, Item 9) with eight screws (Figure 4, Item 6). Connect two cables (Figure 4, Item 5) to connectors (Figure 4, Item 3).
3 4 5
2 1
9 8
6
M10281DAA
Electrical Junction Box Installation.
Connect battery ground cables. (Volume 2, WP 0350) END OF TASK END OF WORK PACKAGE
0641-5/6 blank
TM 9-2320-272-23-4
0642
FIELD MAINTENANCE 400 HZ CONVERTER HARNESS CONDUIT REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Battery ground cables disconnected. (Volume 2, WP 0350) Electrical junction box removed. (WP 0641)
0642-1
TM 9-2320-272-23-4
0642
REMOVAL 1. 2. 3. Remove six screws (Figure 1, Item 2) and clamps (Figure 1, Item 3) from conduits (Figure 1, Items 4 and 7). Remove nuts (Figure 1, Items 5 and 8) and coupling (Figure 1, Item 1) from conduits (Figure 1, Items 4 and 7). Remove conduits (Figure 1, Items 4 and 7) from van body (Figure 1, Item 6).
3 4
8 7
M3077DAA
Figure 1. Converter Harness Conduit Removal. END OF TASK
0642-2
TM 9-2320-272-23-4
0642
INSTALLATION 1. 2. Install nuts (Figure 2, Items 5 and 8) and coupling (Figure 2, Item 1) on conduits (Figure 2, Items 4 and 7). Install conduits (Figure 2, Items 4 and 7) on van body (Figure 2, Item 6) with six clamps (Figure 2, Item 3) and screws (Figure 2, Item 2).
3 4
8 7
M3077DAA
Figure 2. Converter Harness Conduit Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install electrical junction box. (WP 0641) Connect battery ground cables. (Volume 2, WP 0350)
0642-3/4 blank
TM 9-2320-272-23-4
0643
FIELD MAINTENANCE HEATER THERMOSTAT AND 10 KW HEATER THERMOSTAT REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Tool Kit, Electrical Contact (Volume 5, WP 0826, Table 1, Item 55) Equipment Condition Parking brake set. (TM 9-2320-272-10) Battery ground cables disconnected. (Volume 2, WP 0350)
HEATER THERMOSTAT REMOVAL 1. 2. 3. 4. Remove cover (Figure 1, Item 3) from thermostat (Figure 1, Item 5). Remove two screws (Figure 1, Item 4) and thermostat (Figure 1, Item 5) from control center box cover (Figure 1, Item 1). Remove two screws (Figure 1, Item 6) and wires (Figure 1, Item 2) from thermostat (Figure 1, Item 5). Remove thermostat (Figure 1, Item 5) from control center box cover (Figure 1, Item 1).
2 3
4 5 6
M10278DAA
Heater Thermostat and 10 KW Heater Thermostat and 10 KW Heater Thermostat Removal.
0643-1
TM 9-2320-272-23-4
0643
10 KW HEATER THERMOSTAT REMOVAL 1. 2. 3. 4. Remove cover (Figure 2, Item 5) from thermostat (Figure 2, Item 3). Remove two screws (Figure 2, Item 4) and thermostat (Figure 2, Item 3) from control center box cover (Figure 2, Item 7). Disconnect three insulated wire splices (Figure 2, Item 6) from three wires (Figure 2, Items 2 and 1). Discard insulated wire splices. Remove thermostat (Figure 2, Item 3) from control center box cover (Figure 2, Item 7).
3 2 1
4 5
M3078DAA
Figure 2. Heater Thermostat and 10 KW Heater Thermostat and 10 KW Heater Thermostat Removal. END OF TASK
0643-2
TM 9-2320-272-23-4
0643
10 KW HEATER THERMOSTAT INSTALLATION 1. 2. 3. Connect three wires (Figure 3, Items 1 and 2) with three insulated wire splices (Figure 3, Item 6). Position thermostat (Figure 3, Item 3) on control center box cover (Figure 3, Item 7) and install two screws (Figure 3, Item 4). Install cover (Figure 3, Item 5) on thermostat (Figure 3, Item 3).
3 2 1
4 5
M3079DAA
Figure 3. Heater Thermostat and 10 KW Heater Thermostat. END OF TASK
0643-3
TM 9-2320-272-23-4
0643
HEATER THERMOSTAT INSTALLATION 1. 2. 3. Install two wires (Figure 4, Item 2) on thermostat (Figure 4, Item 5) with two screws (Figure 4, Item 6). Position thermostat (Figure 4, Item 5) on control center box cover (Figure 4, Item 1) and install two screws (Figure 4, Item 4). Install cover (Figure 4, Item 3) on thermostat (Figure 4, Item 5).
2 3
4 5 6
M10279DAA
Figure 4. Heater Thermostat and 10 KW Heater Thermostat Installation. END OF TASK FOLLOW-ON MAINTENANCE Connect battery ground cables. (Volume 2, WP 0350) END OF TASK END OF WORK PACKAGE
0643-4
TM 9-2320-272-23-4
0644
FIELD MAINTENANCE BLACKOUT AND EMERGENCY LIGHT FIXTURES REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Battery ground cables disconnected. (Volume 2, WP 0350) Emergency and blackout lamps removed. (WP 0624)
REMOVAL 1. 2. Remove four screws (Figure 1, Item 5) and housing (Figure 1, Item 4) from van ceiling (Figure 1, Item 6). Remove four screws (Figure 1, Item 2), two jumper cables (Figure 1, Item 3), and wiring harness (Figure 1, Item 1) from housing (Figure 1, Item 4).
1
3 6 5 4
M3080DAA
Figure 1. Blackout and Emergency Light Fixtures Removal. END OF TASK
0644-1
TM 9-2320-272-23-4
0644
INSTALLATION 1. 2. Install two jumper cables (Figure 2, Item 3) and wiring harness (Figure 2, Item 1) on housing (Figure 2, Item 4) with four screws (Figure 2, Item 2). Install housing (Figure 2, Item 4) on van ceiling (Figure 2, Item 6) with four screws (Figure 2, Item 5).
1
3 6 5 4
M3081DAA
Blackout and Emergency Light Fixtures Installation.
Install emergency and blackout lamps. (WP 0624) Connect battery ground cables. (Volume 2, WP 0350)
0644-2
TM 9-2320-272-23-4
0645
FIELD MAINTENANCE AIR CONDITIONER MANUAL STARTER SWITCHES REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Tool Kit, Electrical Contact (Volume 5, WP 0826, Table 1, Item 55) Equipment Condition Parking brake set. (TM 9-2320-272-10) Battery ground cables disconnected. (Volume 2, WP 0350)
0645-1
TM 9-2320-272-23-4
0645
REMOVAL
NOTE
Tag wires for installation. 1. 2. 3. Remove covers (Figure 1, Items 4 and 6) from air conditioner starter switch boxes (Figure 1, Items 7 and 8). Remove six wires (Figure 1, Item 2) from six insulated wire splices (Figure 1, Item 1). Discard insulated wire splices. Remove six wires (Figure 1, Item 3) from six insulated wire splices (Figure 1, Item 5). Discard insulated wire splices.
2 1
5 6
7 2 1 5 3
M3082DAA
Figure 1.
Air Conditioner Replacement.
0645-2
TM 9-2320-272-23-4
0645
REMOVAL - Continued 4. 5. 6. 7. 8. Remove two nuts (Figure 2, Item 2) from two connectors (Figure 2, Item 10). Remove two nuts (Figure 2, Item 3) from two connectors (Figure 2, Item 5). Remove two nuts (Figure 2, Item 6) from two connectors (Figure 2, Item 5). Remove four screws (Figure 2, Item 8), manual starter switch box (Figure 2, Item 7), and two connectors (Figure 2, Item 5) from van body (Figure 2, Item 9). Remove four screws (Figure 2, Item 1) and manual starter switch box (Figure 2, Item 4) from van body (Figure 2, Item 9).
10
3 4
8 5 6
7
M3083DAA
Air Conditioner Switch.
0645-3
TM 9-2320-272-23-4
0645
INSTALLATION 1. 2. 3. Feed three wires (Figure 4, Items 1, 10, 11, and 12) into manual starter switch box (Figure 4, Item 14). Install manual starter switch box (Figure 3, Item 4) on two connectors (Figure 3, Item 10) and van body (Figure 3, Item 9) with four screws (Figure 3, Item 1) and two nuts (Figure 3, Item 2). Install two connectors (Figure 3, Item 5) and manual starter switch box (Figure 3, Item 7) on van body (Figure 3, Item 9) and manual starter switch box (Figure 3, Item 4) with four screws (Figure 3, Item 8) and two nuts (Figure 3, Items 3 and 6). Feed three wires (Figure 4, Items 11 and 12) through two connectors (Figure 3, Item 5) and manual starter switch box (Figure 3, Item 7).
4.
10
3 4
8 5 6
7
M3084DAA
Figure 3.
0645-4
TM 9-2320-272-23-4
0645
INSTALLATION - Continued 5. 6. 7. Connect six wires (Figure 4, Items 1 and 10) to six switch leads (Figure 4, Items 2 and 3) with six insulated wire splices (Figure 4, Item 5). Connect six wires (Figure 4, Items 11 and 12) to six switch leads (Figure 4, Items 7 and 8) with six insulated wire splices (Figure 4, Item 9). Install covers (Figure 4, Items 4 and 6) on air conditioner starter switch boxes (Figure 4, Items 13 and 14).
5 14 6 9 13 7 9 10 12
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE Connect battery ground cables. (Volume 2, WP 0350) END OF TASK END OF WORK PACKAGE
11
M3085DAA
0645-5/6 blank
TM 9-2320-272-23-4
0646
FIELD MAINTENANCE FLUORESCENT LIGHT FIXTURES REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Tool Kit, Electrical Contact (Volume 5, WP 0826, Table 1, Item 55) Materials/Parts Lockwasher (Volume 5, WP 0827, Table 1, Item 407) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Battery ground cables disconnected. (Volume 2, WP 0350) Fluorescent light tubes removed. (WP 0623)
0646-1
TM 9-2320-272-23-4
0646
REMOVAL
NOTE
All eight fluorescent light fixtures are removed and installed the same way. This procedure covers one fluorescent light fixture. 1. 2. 3. Remove 20 screws (Figure 1, Item 8) and light fixture body (Figure 1, Item 9) from van ceiling (Figure 1, Item 10). Remove nut (Figure 1, Item 7), lockwasher (Figure 1, Item 6), screw (Figure 1, Item 1), and wire (Figure 1, Item 5) from light fixture body (Figure 1, Item 9). Discard lockwasher. Remove two wires (Figure 1, Items 2 and 4) and insulated wire splices (Figure 1, Item 3) from light fixture body (Figure 1, Item 9). Discard insulated wire splices.
4 3 5 1 2 6 7
10 9
8
Figure 1. END OF TASK Fluorescent Light.
M3086DAA
0646-2
TM 9-2320-272-23-4
0646
INSTALLATION 1. 2. 3. Install wire (Figure 2, Item 5) on light fixture body (Figure 2, Item 9) with nut (Figure 2, Item 7), lockwasher (Figure 2, Item 6), and screw (Figure 2, Item 1). Install two wires (Figure 2, Items 2 and 4) with insulated wire splices (Figure 2, Item 3). Install light fixture body (Figure 2, Item 9) on van ceiling (Figure 2, Item 10) with 20 screws (Figure 2, Item 8).
4 3 5 1 2 6 7
10 9
8
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Connect battery ground cables. (Volume 2, WP 0350) Install fluorescent light tubes. (WP 0623) Fluorescent Light.
M3090DAA
0646-3/4 blank
TM 9-2320-272-23-4
0647
FIELD MAINTENANCE 400 HZ CONVERTER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Gasket (Volume 5, WP 0827, Table 1, Item 263) Qty: 1 Locknut (Volume 5, WP 0827, Table 1, Item 276) Qty: 2 Lockwasher (Volume 5, WP 0827, Table 1, Item 255) Qty: 2 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Battery ground cables disconnected. (Volume 2, WP 0350)
0647-1
TM 9-2320-272-23-4
0647
REMOVAL 1. 2. 3. 4. 5. 6. 7. Remove four screws (Figure 1, Item 17), cover (Figure 1, Item 18), and gasket (Figure 1, Item 19) from converter (Figure 1, Item 3). Discard gasket. Remove six nuts (Figure 1, Item 1) and wires (Figure 1, Item 2) from converter (Figure 1, Item 3). Remove two lockwashers (Figure 1, Item 16) and wiring harnesses (Figure 1, Items 14 and 15) from converter (Figure 1, Item 3). Remove four nuts (Figure 1, Item 10), washers (Figure 1, Item 11), and screws (Figure 1, Item 4) from support bracket (Figure 1, Item 12). Remove converter (Figure 1, Item 3) from support bracket (Figure 1, Item 12). Remove two locknuts (Figure 1, Item 13), U-bolt (Figure 1, Item 8), and nuts (Figure 1, Item 9) from support bracket (Figure 1, Item 12). Discard locknuts. Remove four nuts (Figure 1, Item 6), screws (Figure 1, Item 7), and support bracket (Figure 1, Item 12) from van body (Figure 1, Item 5).
0647-2
TM 9-2320-272-23-4
0647
REMOVAL - Continued
1 2
19
18 3 17 3 4
5 16
14 15 13 12 6
11 10 7 9 8
M3091DAA
400 Hz Converter Removal.
0647-3
TM 9-2320-272-23-4
0647
INSTALLATION 1. 2. 3. 4. 5. 6. Install support bracket (Figure 2, Item 12) on van body (Figure 2, Item 5) with four screws (Figure 2, Item 7) and nuts (Figure 2, Item 6). Install two nuts (Figure 2, Item 9) and U-bolt (Figure 2, Item 8) on support bracket (Figure 2, Item 12) with locknuts (Figure 2, Item 13). Install converter (Figure 2, Item 3) on support bracket (Figure 2, Item 12) with four screws (Figure 2, Item 4), washers (Figure 2, Item 11), and nuts (Figure 2, Item 10). Install two wiring harnesses (Figure 2, Items 14 and 15) on converter (Figure 2, Item 3) with two lockwashers (Figure 2, Item 16). Install six wires (Figure 2, Item 2) on converter (Figure 2, Item 3) with six nuts (Figure 2, Item 1). Install gasket (Figure 2, Item 19) and cover (Figure 2, Item 18) on converter (Figure 2, Item 3) with four screws (Figure 2, Item 17).
0647-4
TM 9-2320-272-23-4
0647
1 2
19
18 3 17 3 4
5 16
14 15 13 12 6
11 10 7 9 8
M3092DAA
400 Hz Converter Installation.
0647-5
TM 9-2320-272-23-4
0647
0647-6
TM 9-2320-272-23-4
0648
FIELD MAINTENANCE ELECTRICAL LOAD CENTER CONDUIT REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Sealing Compound (Volume 5, WP 0825, Table 1, Item 55) Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10)
REMOVAL 1. 2. 3. Remove cables (Figure 1, Items 4 and 5) from connectors (Figure 1, Items 3 and 7). Remove eight screws (Figure 1, Item 6) and cover (Figure 1, Item 8) from junction box (Figure 1, Item 9). Disconnect wiring harness (Figure 1, Items 1 and 2) from connectors (Figure 1, Items 3 and 7).
4 1 2 9 3
6
M10283DAA
Figure 1. Electrical Load Center Conduit Removal.
0648-1
TM 9-2320-272-23-4
0648
REMOVAL - Continued 4. 5. 6. Remove six screws (Figure 2, Item 12) and cover (Figure 2, Item 13) from load center (Figure 2, Item 3). Pull wiring harnesses (Figure 2, Items 1 and 2) from conduit (Figure 2, Item 9) and load center (Figure 2, Item 3). Remove nut (Figure 2, Item 6), coupling (Figure 2, Item 11), and nut (Figure 2, Item 10) from conduit (Figure 2, Item 9) and load center (Figure 2, Item 3).
NOTE
Assistant will help with Step (7). 7. Remove two nuts (Figure 2, Item 7) and coupling (Figure 2, Item 8) from conduits (Figure 2, Items 4 and 9). Remove conduit (Figure 2, Item 9) from van body (Figure 2, Item 5).
2 1 3
13
12
11 10
6 9 5
7 8 7 4
M3093DAA
Electrical Load Center Conduit Removal.
0648-2
TM 9-2320-272-23-4
0648
INSTALLATION 1. 2. 3. 4. 5. Position conduit (Figure 3, Item 9) on van body (Figure 3, Item 5). Install coupling (Figure 3, Item 8) on conduits (Figure 3, Items 4 and 9) with two nuts (Figure 3, Item 7). Install coupling (Figure 3, Item 11) on conduit (Figure 3, Item 9) and load center (Figure 3, Item 3) with nut (Figure 3, Items 6 and 10). Route wiring harnesses (Figure 3, Items 1 and 2) through conduit (Figure 3, Item 9) and load center (Figure 3, Item 3). Install cover (Figure 3, Item 13) on load center (Figure 3, Item 3) with six screws (Figure 3, Item 12).
4 1 2 9 3
6
M10284DAA
Figure 3. Electrical Load Center Conduit Installation.
0648-3
TM 9-2320-272-23-4
0648
INSTALLATION - Continued 6. Connect wiring harnesses (Figure 4, Items 1 and 2) to connectors (Figure 4, Items 3 and 7).
NOTE
Apply sealing compound before performing Step (7). 7. 8. Install cover (Figure 4, Item 8) on junction box (Figure 4, Item 9) with eight screws (Figure 4, Item 6). Install cables (Figure 4, Items 4 and 5) on connectors (Figure 4, Items 3 and 7).
2 1 3
13
12
11 10
6 9 5
7 8 7 4
M10138DAA
Figure 4. Electrical Load Center Conduit Installation. END OF TASK END OF WORK PACKAGE
0648-4
TM 9-2320-272-23-4
0649
FIELD MAINTENANCE FRONT WALL REGISTERS REPLACEMENT
REMOVAL
NOTE
All four front wall registers are replaced the same way. This procedure covers one register. Remove four screws (Figure 1, Item 2) and register (Figure 1, Item 3) from front wall (Figure 1, Item 1).
M4025DAA
Front Wall Registers Removal.
0649-1
TM 9-2320-272-23-4
0649
INSTALLATION Install register (Figure 2, Item 3) on front wall (Figure 2, Item 1) with four screws (Figure 2, Item 2).
M4026DAA
Figure 2. Front Wall Registers Installation. END OF TASK END OF WORK PACKAGE
0649-2
TM 9-2320-272-23-4
0650
FIELD MAINTENANCE BONNET ACCESS DOOR MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Tool Kit, Blind, Fastener (Volume 5, WP 0826, Table 1, Item 54) Materials/Parts Primer Coating (Volume 5, WP 0825, Table 1, Item 52) Sealing Compound (Volume 5, WP 0825, Table 1, Item 61) Rivet (Volume 5, WP 0827, Table 1, Item 441) Qty: 66 Materials/Parts (cont.) Seal (Volume 5, WP 0827, Table 1, Item 54) Qty: 1 Seal (Volume 5, WP 0827, Table 1, Item 236) Qty: 1 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Bonnet control rod removed. (WP 0613)
0650-1
TM 9-2320-272-23-4
0650
REMOVAL
NOTE
Assistant will help with Step. Remove 12 screws (Figure 1, Item 1) and access door assembly (Figure 1, Item 2) from bonnet frame (Figure 1, Item 3).
0650-2
TM 9-2320-272-23-4
0650
REMOVAL - Continued
1 2
3
M4027DAA
Bonnet Access Door Removal.
0650-3
TM 9-2320-272-23-4
0650
DISASSEMBLY 1. 2. 3. 4. Remove 12 screws (Figure 2, Item 1), hinge (Figure 2, Item 2), and seal (Figure 2, Item 21) from door frame (Figure 2, Item 17). Discard seal. Remove four screws (Figure 2, Item 5) and two angle brackets (Figure 2, Item 4) from inner panel (Figure 2, Item 3). Remove four screws (Figure 2, Item 7), rod (Figure 2, Item 8), and holder bracket (Figure 2, Item 6) from inner panel (Figure 2, Item 3). Remove screw (Figure 2, Item 11), two nuts (Figure 2, Item 9), screws (Figure 2, Item 12), and bracket (Figure 2, Item 10) from inner panel (Figure 2, Item 3).
NOTE
Assistant will help with Step (5). 5. Remove 33 nuts (Figure 2, Item 13), screws (Figure 2, Item 18), 74 rivets (Figure 2, Item 19), outer panel (Figure 2, Item 20), three retainers (Figure 2, Item 14), and seal (Figure 2, Item 16) from door frame (Figure 2, Item 17). Discard seal and rivets.
NOTE
Perform Step (6) if inner panel is to be replaced. 6. Remove 74 rivets (Figure 2, Item 15) and inner panel (Figure 2, Item 3) from door frame (Figure 2, Item 17). Discard rivets.
0650-4
TM 9-2320-272-23-4
0650
1 4 2 3
6 5
7 8 7
21 5 10 9 11 15 20 13 14 13 14 16 12 9 4
18
17
19 18
M4028DAA
Bonnet Access Door Disassembly.
0650-5
TM 9-2320-272-23-4
0650
CLEANING AND INSPECTION 1. 2. 3. 4. 5. 6. 7. For General Cleaning Instructions, refer to (Volume 5, WP 0817). Inspect hinge (Figure 3, Item 1) for breaks and proper operation. Replace hinge if damaged. Inspect three retainers (Figure 3, Item 6) for bends and breaks. Replace if bent or broken. Inspect angle brackets (Figure 3, Item 3), holder bracket (Figure 3, Item 4), and rod (Figure 3, Item 5) for cracks and breaks. Replace if cracked or broken. Inspect outer panel (Figure 3, Item 8) for tears and punctures. Replace outer panel if torn or punctured. Inspect inner panel (Figure 3, Item 2) for tears and punctures. Replace inner panel if torn or punctured. Inspect door frame (Figure 3, Item 7) for bend, cracks, and breaks. Replace door frame if bent, cracked, or broken.
0650-6
TM 9-2320-272-23-4
0650
CLEANING AND INSPECTION - Continued

4 3 5 1 2
M4029DAA
Figure 3. Bonnet Access Door Cleaning and Inspection. END OF TASK
0650-7
TM 9-2320-272-23-4
0650
ASSEMBLY
NOTE
Insulate areas of dissimilar metal-to-metal contact with zinc chromate primer. Apply sealing compound to exterior joints prior to installation. Insulate all enclosed structure with fibrous glass felt insulation. Perform Step (1) only if inner panel was removed. Assistant will help with Steps (1) and (2). 1. 2. Install inner panel (Figure 4, Item 3) on door frame (Figure 4, Item 17) with 74 rivets (Figure 4, Item 15). Install seal (Figure 4, Item 16), three retainers (Figure 4, Item 14), and outer panel (Figure 4, Item 20) on door frame (Figure 4, Item 17) with 33 screws (Figure 4, Item 18), nuts (Figure 4, Item 13), and 74 rivets (Figure 4, Item 19). Install holder bracket (Figure 4, Item 6) and rod (Figure 4, Item 8) on inner panel (Figure 4, Item 3) with four screws (Figure 4, Item 7). Install screw (Figure 4, Item 11) and two nuts (Figure 4, Item 9) on bracket (Figure 4, Item 10).
3. 4.
NOTE
Angle bracket can be installed on either side of door. 5. 6. 7. Install bracket (Figure 4, Item 10) on inner panel (Figure 4, Item 3) with two screws (Figure 4, Item 12). Install two angle brackets (Figure 4, Item 4) on inner panel (Figure 4, Item 3) with four screws (Figure 4, Item 5). Install seal (Figure 4, Item 21) and hinge (Figure 4, Item 2) on door frame (Figure 4, Item 17) with 12 screws (Figure 4, Item 1).
0650-8
TM 9-2320-272-23-4
0650
1 4 2 3
6 5
7 8 7
21 5 10 9 11 15 20 13 14 13 14 16 12 9 4
18
17
19 18
M4030DAA
Bonnet Access Door Assembly.
0650-9
TM 9-2320-272-23-4
0650
INSTALLATION
NOTE
Assistant will help with Step. Install access door assembly (Figure 5, Item 2) on bonnet frame (Figure 5, Item 3) with 12 screws (Figure 5, Item 1).
1
3
M4031DAA
Figure 5. Bonnet Access Door Installation. END OF TASK FOLLOW-ON MAINTENANCE Install bonnet control rod. (WP 0613) END OF TASK END OF WORK PACKAGE
0650-10
TM 9-2320-272-23-4
0651
FIELD MAINTENANCE BONNET DOOR MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Tool Kit, Blind, Fastener (Volume 5, WP 0826, Table 1, Item 54) Materials/Parts Primer Coating (Volume 5, WP 0825, Table 1, Item 52) Sealing Compound (Volume 5, WP 0825, Table 1, Item 61) Rivet (Volume 5, WP 0827, Table 1, Item 308) Qty: 48 Rivet (Volume 5, WP 0827, Table 1, Item 441) Qty: 52 Seal (Volume 5, WP 0827, Table 1, Item 25) Qty: 1 Materials/Parts (cont.) Seal, 24 in. (Volume 5, WP 0827, Table 1, Item 24) Qty: 1 Seal, 27 in. (Volume 5, WP 0827, Table 1, Item 236) Qty: 1 Seal, 78 in. (Volume 5, WP 0827, Table 1, Item 24) Qty: 1 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10)
0651-1
TM 9-2320-272-23-4
0651
REMOVAL
NOTE
Left and right bonnet doors are replaced the same way. This procedure covers the left side. 1. Remove two screws (Figure 1, Item 4) and washers (Figure 1, Item 5) from bonnet door (Figure 1, Item 3) and bonnet (Figure 1, Item 1).
NOTE
Assistant will help with Step (2). 2. 3. Remove seven screws (Figure 1, Item 2) and bonnet door (Figure 1, Item 3) from bonnet (Figure 1, Item 1). Position bonnet door (Figure 1, Item 3) squarely on four jack stands with outer panel facing upwards.
0651-2
TM 9-2320-272-23-4
0651
REMOVAL - Continued
1 2 1 3
M4032DAA
Bonnet Door Removal.
0651-3
TM 9-2320-272-23-4
0651
DISASSEMBLY 1. 2. Remove six screws (Figure 2, Item 16), spacer plate (Figure 2, Item 15), seal (Figure 2, Item 14), hinge (Figure 2, Item 13), and seal (Figure 2, Item 12) from frame (Figure 2, Item 7). Discard seals. Remove 18 nuts (Figure 2, Item 28), screws (Figure 2, Item 11), and two retainers (Figure 2, Item 4) from outer panel (Figure 2, Item 10), frame (Figure 2, Item 7), and seal (Figure 2, Item 3).
NOTE
Assistant will help with Step (3). 3. 4. 5. 6. 7. Remove 17 rivets (Figure 2, Item 9) and outer panel (Figure 2, Item 10) from frame (Figure 2, Item 7). Discard rivets. Remove 24 rivets (Figure 2, Item 27), intake assembly (Figure 2, Item 17), intake panel (Figure 2, Item 26) (if present), and preformed cork (Figure 2, Item 1) from inner panel (Figure 2, Item 2). Discard rivets and cork. Remove 14 rivets (Figure 2, Item 21), two channels (Figure 2, Item 20), channel seals (Figure 2, Item 19), and channels (Figure 2, Item 18) from intake assembly (Figure 2, Item 17). Discard rivets and channel seals. Remove ten rivets (Figure 2, Item 22), two channels (Figure 2, Item 23), channel seals (Figure 2, Item 24), and channels (Figure 2, Item 25) from intake assembly (Figure 2, Item 17). Discard rivets and channel seals. Remove seven nuts (Figure 2, Item 5), screws (Figure 2, Item 8), retainer (Figure 2, Item 6), and seal (Figure 2, Item 3) from frame (Figure 2, Item 7). Discard seal.
NOTE
Assistant will help with Step (8). 8. Remove 33 rivets (Figure 2, Item 29), two rivets (Figure 2, Item 30), and inner panel (Figure 2, Item 2) from frame (Figure 2, Item 7). Discard rivets.
0651-4
TM 9-2320-272-23-4
0651
3 30
6 7
29 4
28 9 27
23 22 21
24
25 26
10 11
20 19
18
17 16 15 14 13
M4033DAA
12
Bonnet Door Disassembly. 0651-5

TM 9-2320-272-23-4
0651
CLEANING AND INSPECTION 1. 2. 3. 4. 5. 6. 7. 8. For General Cleaning Instructions, refer to (Volume 5, WP 0817). Inspect hinge (Figure 3, Item 9) for breaks, corrosion, and proper operation. Replace hinge if damaged. Inspect retainers (Figure 3, Item 8) and (Figure 3, Item 5) and spacer plate (Figure 3, Item 10) for bends and breaks. Replace retainers and and space plate if bent or broken. Inspect outer panel (Figure 3, Item 4) and inner panel (Figure 3, Item 7) for tears, cracks, and punctures. Replace outer panel and inner panel if torn, cracked, or punctured. Inspect intake assembly (Figure 3, Item 11) for cracks and bends. Replace intake assembly if cracked or bent. Inspect intake panel (Figure 3, Item 3) for bends and breaks. Replace intake panel if bent or broken. Inspect channels (Figure 3, Items 1, 2, 12, and 13) for bends and breaks. Replace if bent or broken. Inspect frame (Figure 3, Item 6) for bends, breaks, cracks, and warpage. Replace entire bonnet door assembly if frame is damaged.
0651-6
TM 9-2320-272-23-4
0651
5 13 12 11 6
10
M4034DAA
Bonnet Door Cleaning and Inspection.
0651-7
TM 9-2320-272-23-4
0651
ASSEMBLY
NOTE
Insulate areas of dissimilar metal-to-metal contact with zinc chromate primer. Apply sealing compound to exterior joints prior to installation. Insulate all enclosed structure with fibrous glass felt insulation. Assistant will help with Step (1). 1. 2. 3. 4. Install inner panel (Figure 4, Item 2) on frame (Figure 4, Item 7) with 33 rivets (Figure 4, Item 29) and two rivets (Figure 4, Item 30). Install seal (Figure 4, Item 3) and retainer (Figure 4, Item 6) on frame (Figure 4, Item 7) with seven screws (Figure 4, Item 8) and nuts (Figure 4, Item 5). Install two channel seals (Figure 4, Item 24), channels (Figure 4, Item 23), and channels (Figure 4, Item 25) on intake assembly (Figure 4, Item 17) with ten rivets (Figure 4, Item 22). Install two channel seals (Figure 4, Item 19), channels (Figure 4, Item 18), and channels (Figure 4, Item 20) on intake assembly (Figure 4, Item 17) with 14 rivets (Figure 4, Item 21).
NOTE
Assistant will help with Steps (6) and (7). 5. 6. 7. 8. Install preformed cork (Figure 4, Item 1), intake panel (Figure 4, Item 26) (if present), and intake assembly (Figure 4, Item 17) on inner panel (Figure 4, Item 2) with 24 rivets (Figure 4, Item 27). Install outer panel (Figure 4, Item 10) on frame (Figure 4, Item 7) with 17 rivets (Figure 4, Item 9). Install two retainers (Figure 4, Item 4) in seal (Figure 4, Item 3) with 18 screws (Figure 4, Item 11) and nuts (Figure 4, Item 28). Install seal (Figure 4, Item 12), hinge (Figure 4, Item 13), spacer plate (Figure 4, Item 15), and seal (Figure 4, Item 14) on frame (Figure 4, Item 7) with six screws (Figure 4, Item 16). Ensure hinge is flush with top of door.
0651-8
TM 9-2320-272-23-4
0651
1 5
6 7
8 4 30
29 28 9 27
22 21
23
24
25 26
10 11
20 19 12 18 17 16 15
13 14
M4035DAA
Bonnet Door Assembly.
0651-9
TM 9-2320-272-23-4
0651
INSTALLATION
NOTE
Assistant will help with Step. Install bonnet door (Figure 5, Item 3) on bonnet (Figure 5, Item 1) with seven screws (Figure 5, Item 2), two screws (Figure 5, Item 4), and washers (Figure 5, Item 5).
1 2 1 3
M4036DAA
Figure 5. Bonnet Door Installation. END OF TASK END OF WORK PACKAGE
0651-10
TM 9-2320-272-23-4
0652
FIELD MAINTENANCE AIR CONDITIONER REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Chain Assembly (Volume 5, WP 0826, Table 1, Item 15) Lifting Device Materials/Parts Cotter Pin (Volume 5, WP 0827, Table 1, Item 341) Qty: 1 Lockwasher (Volume 5, WP 0827, Table 1, Item 424) Qty: 2 Personnel Required (3) Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Cab tarpaulin and bows removed. (TM 9-2320-272-10) Windshield lowered. (TM 9-2320-272-10) Companion seat lowered. (TM 9-2320-272-10) External power source disconnected. (TM 9-2320-272-10) Battery ground cables disconnected. (Volume 2, WP 0350) Air conditioner drain tube removed. (WP 0633) Bonnet door removed. (WP 0651)
0652-1
TM 9-2320-272-23-4
0652
REMOVAL
NOTE
Screw quantity for Steps (1), (2), and (4) may differ from vehicle to vehicle. Record quantity removed for installation. 1. 2. 3. 4. Remove 16 screws (Figure 1, Item 6) and lower angle bracket (Figure 1, Item 5) from lower panel mounting angle (Figure 1, Item 7). Remove 12 screws (Figure 1, Item 9) and lower panel mounting angle (Figure 1, Item 7) from bonnet (Figure 1, Item 11). Remove four screws (Figure 1, Item 8) and two mounting angles (Figure 1, Item 4) from bonnet (Figure 1, Item 11). Remove 14 screws (Figure 1, Item 3), snap (Figure 1, Item 2), and condenser guard (Figure 1, Item 1) from air conditioner (Figure 1, Item 10).
0652-2
TM 9-2320-272-23-4
0652
REMOVAL - Continued
1 8 2
3 6 4 8 9 5
11
10 7
M4037DAA
Figure 1.
Air Conditioner Removal.
0652-3
TM 9-2320-272-23-4
0652
REMOVAL - Continued 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Remove 16 screws (Figure 2, Item 2) and top enclosure (Figure 2, Item 7) from bonnet (Figure 2, Item 13) and air conditioner (Figure 2, Item 12). Remove 12 screws (Figure 2, Item 9) and right enclosure (Figure 2, Item 8) from bonnet (Figure 2, Item 13) and air conditioner (Figure 2, Item 12). Remove four screws (Figure 2, Item 6), plate (Figure 2, Item 5), and bellows (Figure 2, Item 3) from left enclosure (Figure 2, Item 1). Remove ten screws (Figure 2, Item 4) and left enclosure (Figure 2, Item 1) from bonnet (Figure 2, Item 13) and air conditioner (Figure 2, Item 12). Remove cotter pin (Figure 2, Item 16) and door rod (Figure 2, Item 14) from swing arm (Figure 2, Item 15). Discard cotter pin. Remove seven screws (Figure 2, Item 11) and bottom enclosure (Figure 2, Item 10) from bonnet (Figure 2, Item 13) and air conditioner (Figure 2, Item 12). Disconnect power cable (Figure 2, Item 26) from air conditioner (Figure 2, Item 12). Remove screw (Figure 2, Item 28), ground cable (Figure 2, Item 29), and lockwasher (Figure 2, Item 27) from air conditioner (Figure 2, Item 12). Discard lockwasher. Remove screw (Figure 2, Item 25), ground cable (Figure 2, Item 29), and lockwasher (Figure 2, Item 30) from mounting plate (Figure 2, Item 20) and bonnet floor (Figure 2, Item 31). Discard lockwasher. Remove five screws (Figure 2, Item 24) from mounting plate (Figure 2, Item 20) and bonnet floor (Figure 2, Item 31). Remove six screws (Figure 2, Item 23) from mounting plate (Figure 2, Item 19) and bonnet floor (Figure 2, Item 31).
WARNING
All personnel must stand clear during lifting operations. A shifting or swinging load may cause injury to personnel. Failure to comply may result in injury or death to personnel.
NOTE
Two assistants will help with Step (16). 16. Attach chains (Figure 2, Item 18) to lifting device (Figure 2, Item 17) and four lifting brackets (Figure 2, Item 22) on air conditioner (Figure 2, Item 12) and remove air conditioner from bonnet (Figure 2, Item 13). Position air conditioner for access to bottom of unit. Remove six screws (Figure 2, Item 21) and mounting plates (Figure 2, Items 19 and 20) from air conditioner (Figure 2, Item 12).
17.
0652-4
TM 9-2320-272-23-4
0652
REMOVAL - Continued
16 15 2 1 14 6 5 4 9 9 8 3 2 7
11 14 13 12 10
17 18
18 23 24 20 25 26
12
22
19
12
27
30
29
28
31 19 13 21 20
M4038DAA
Air Conditioner Removal.
0652-5
TM 9-2320-272-23-4
0652
INSTALLATION 1. Install mounting plates (Figure 3, Items 3 and 4) on air conditioner (Figure 3, Item 8) with six screws (Figure 3, Item 5).
WARNING
All personnel must stand clear during lifting operations. A shifting or swinging load may cause injury to personnel. Failure to comply may result in injury or death to personnel.
NOTE
Two assistants will help with Step (2). 2. 3. 4. 5. 6. 7. 8. 9. Attach chains (Figure 3, Item 2) to lifting device (Figure 3, Item 1) and four lifting brackets (Figure 3, Item 7). Position air conditioner (Figure 3, Item 8) in bonnet (Figure 3, Item 6). Install mounting plate (Figure 3, Item 3) on bonnet floor (Figure 3, Item 17) with six screws (Figure 3, Item 9). Install ground cable (Figure 3, Item 15) on mounting plate (Figure 3, Item 4) and bonnet floor (Figure 3, Item 17) with lockwasher (Figure 3, Item 16), and screw (Figure 3, Item 11). Install ground cable (Figure 3, Item 15) on air conditioner (Figure 3, Item 8) with lockwasher (Figure 3, Item 13), and screw (Figure 3, Item 14). Install mounting plate (Figure 3, Item 4) on bonnet floor (Figure 3, Item 17) with five screws (Figure 3, Item 10). Connect power cable (Figure 3, Item 12) to air conditioner (Figure 3, Item 8). Remove lifting device (Figure 3, Item 1) and chains (Figure 3, Item 2) from air conditioner (Figure 3, Item 8).
0652-6
TM 9-2320-272-23-4
0652
1 2 2 9 10 4 8 11 12
13
16
15
14
17 3 5 4
M4039DAA
Figure 3.
Air Conditioner Installation.
0652-7
TM 9-2320-272-23-4
0652
INSTALLATION - Continued 10. 11. 12. Install bottom enclosure (Figure 4, Item 5) on bonnet (Figure 4, Item 7) and air conditioner (Figure 4, Item 6) with seven screws (Figure 4, Item 6). Install door rod (Figure 4, Item 9) on swing arm (Figure 4, Item 15) with cotter pin (Figure 4, Item 16). Install left enclosure (Figure 4, Item 10) on bonnet (Figure 4, Item 7) and air conditioner (Figure 4, Item 8) with ten screws (Figure 4, Item 11). Ensure door rod (Figure 4, Item 9) is positioned through bellows (Figure 4, Item 12). Install bellows (Figure 4, Item 12) on left enclosure (Figure 4, Item 10) with plate (Figure 4, Item 13) and four screws (Figure 4, Item 14). Install right enclosure (Figure 4, Item 3) on bonnet (Figure 4, Item 7) and air conditioner (Figure 4, Item 8) with 12 screws (Figure 4, Item 4). Install top enclosure (Figure 4, Item 2) on bonnet (Figure 4, Item 7) and air conditioner (Figure 4, Item 8) with 16 screws (Figure 4, Item 1).
13. 14. 15.
1 16 1 12 2
15
9 10 11 4 13
14
6 9 8 7 5
M4040DAA
Figure 4.
0652-8
TM 9-2320-272-23-4
0652
NOTE
Screw quantity for Steps (16), (18), and (19) may differ from vehicle to vehicle. Install screws as recorded. 16. 17. 18. 19. Install condenser guard (Figure 5, Item 1) on air conditioner (Figure 5, Item 10) with snap (Figure 5, Item 2) and 14 screws (Figure 5, Item 3). Install two mounting angles (Figure 5, Item 4) on bonnet (Figure 5, Item 11) with four screws (Figure 5, Item 8). Install lower panel mounting angle (Figure 5, Item 7) on bonnet (Figure 5, Item 11) with 12 screws (Figure 5, Item 9). Install lower angle bracket (Figure 5, Item 5) on bonnet (Figure 5, Item 11) and two mounting angles (Figure 5, Item 4) with 16 screws (Figure 5, Item 6).
1
4 8 9
11
10 7
M4041DAA
0652-9
TM 9-2320-272-23-4
0652
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. Install bonnet door. (WP 0651) Install air conditioner drain tube. (WP 0633) Connect battery ground cables. (Volume 2, WP 0350) Connect external power source. (TM 9-2320-272-10) Raise companion seat. (TM 9-2320-272-10) Raise windshield. (TM 9-2320-272-10) Install cab tarpaulin and bows. (TM 9-2320-272-10)
0652-10
TM 9-2320-272-23-4
0653
FIELD MAINTENANCE MAIN WIRING HARNESS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Battery ground cables disconnected. (Volume 2, WP 0350) Fluorescent light tubes removed. (WP 0623) Equipment Condition (cont.) Emergency/blackout lamp and light removed. (WP 0624) Blackout light switch and 110-volt receptacle removed. (WP 0625)
0653-1
TM 9-2320-272-23-4
0653
REMOVAL
NOTE
The left and right main wiring harnesses are replaced the same way. This procedure covers the right main wiring harness. Tag wires for installation. 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove six screws (Figure 1, Item 23) and cover (Figure 1, Item 24) from load center (Figure 1, Item 5). Remove three setscrews (Figure 1, Item 6) and wires (Figure 1, Item 25) from relay (Figure 1, Item 7). Remove setscrew (Figure 1, Item 21) and wire (Figure 1, Item 22) from neutral bus (Figure 1, Item 8). Remove three screws (Figure 1, Item 19) and five wires (Figure 1, Item 20) from 20 amp circuit breakers (Figure 1, Item 9). Remove screw (Figure 1, Item 1) and clamp (Figure 1, Item 2) from plate (Figure 1, Item 4) and wiring harnesses (Figure 1, Item 3). Remove 12 screws (Figure 1, Item 12) and clamps (Figure 1, Item 11) from van ceiling (Figure 1, Item 17) and main wiring harness (Figure 1, Item 10). Remove grommet (Figure 1, Item 13) from van side panel (Figure 1, Item 16). Remove three screws (Figure 1, Item 15) and wire clip (Figure 1, Item 14) from van side panel (Figure 1, Item 16). Remove main wiring harness (Figure 1, Item 10) from van body (Figure 1, Item 18).
0653-2
TM 9-2320-272-23-4
0653
REMOVAL - Continued
4 1 2 3
25 24 23 6 5
7 22 21 9 20 19 18 8
17
16
10 11 15 14 13
Figure 1. END OF TASK 0653-3 Main Wiring Harness Removal.
M4042DAA
12
TM 9-2320-272-23-4
0653
INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. Position main wiring harness (Figure 2, Item 10) on van body (Figure 2, Item 18). Install wire clip (Figure 2, Item 14) on side panel (Figure 2, Item 16) of van body (Figure 2, Item 18) with three screws (Figure 2, Item 15). Install grommet (Figure 2, Item 13) on side panel (Figure 2, Item 16). Install 12 clamps (Figure 2, Item 11) on main wiring harness (Figure 2, Item 10) and van ceiling (Figure 2, Item 17) with 12 screws (Figure 2, Item 12). Install clamp (Figure 2, Item 2) on harnesses (Figure 2, Item 3) and plate (Figure 2, Item 4) with screw (Figure 2, Item 1). Install five wires (Figure 2, Item 20) on 20 amp circuit breakers (Figure 2, Item 9) with three screws (Figure 2, Item 19). Install wire (Figure 2, Item 22) on neutral bus (Figure 2, Item 8) with setscrew (Figure 2, Item 21). Install three wires (Figure 2, Item 25) on relay (Figure 2, Item 7) with three setscrews (Figure 2, Item 6). Install cover (Figure 2, Item 24) on load center (Figure 2, Item 5) with six screws (Figure 2, Item 23).
0653-4
TM 9-2320-272-23-4
0653
4 1 2 3
25 24 23 6 5
7 22 21 9 20 19 18 8
17
16
10 11 15 14 13
Figure 2. END OF TASK 0653-5 Main Wiring Harness Installation.
M4043DAA
12
TM 9-2320-272-23-4
0653
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install blackout light switch and 110-volt receptacle. (WP 0625) Install emergency/blackout lamp and light. (WP 0624) Install fluorescent light tubes. (WP 0623) Connect battery ground cables. (Volume 2, WP 0350)
0653-6
TM 9-2320-272-23-4
0654
FIELD MAINTENANCE VAN AIR CONDITIONER WIRING HARNESS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Battery ground cables disconnected. (Volume 2, WP 0350) Ceiling filler and side panels removed.
0654-1
TM 9-2320-272-23-4
0654
REMOVAL
NOTE
Tag cables for installation. 1. 2. 3. 4. 5. Remove 12 screws (Figure 1, Item 21) and clamps (Figure 1, Item 22) from wiring harness (Figure 1, Item 23) and van ceiling (Figure 1, Item 1). Disconnect plug (Figure 1, Item 2) from air conditioner (Figure 1, Item 3). Remove six screws (Figure 1, Item 15) and cover (Figure 1, Item 14) from load center (Figure 1, Item 9). Remove screw (Figure 1, Item 17) and clamp (Figure 1, Item 18) from wiring harnesses (Figure 1, Items 13 and 16) and plate (Figure 1, Item 4). Remove nut (Figure 1, Item 19), screw (Figure 1, Item 7), two washers (Figure 1, Item 8), cable assembly (Figure 1, Item 6), ground cable (Figure 1, Item 5), and wiring harness cable (Figure 1, Item 20) from load center (Figure 1, Item 9). Remove three screws (Figure 1, Item 11) and wiring harness cables (Figure 1, Item 12) from 30 amp circuit breaker (Figure 1, Item 10). Remove wiring harness (Figure 1, Item 13) from load center (Figure 1, Item 9).
6. 7.
0654-2
TM 9-2320-272-23-4
0654
REMOVAL - Continued
23 22 21 3 8 19 18 17 16 15 5 6 20 4
7 14 9 13 12 10 11
M4044DAA
Figure 1. Van Air Conditioner Wiring Harness Removal. END OF TASK 0654-3
TM 9-2320-272-23-4
0654
INSTALLATION 1. 2. 3. Position wiring harness (Figure 2, Item 13) on load center (Figure 2, Item 9). Install three wiring harness cables (Figure 2, Item 12) on 30 amp circuit breaker (Figure 2, Item 10) with three screws (Figure 2, Item 11). Install wiring harness cable (Figure 2, Item 20), ground cable (Figure 2, Item 5), and cable assembly (Figure 2, Item 6) on load center (Figure 2, Item 9) with screw (Figure 2, Item 7), two washers (Figure 2, Item 8), and nut (Figure 2, Item 19). Install clamp (Figure 2, Item 18) on wiring harnesses (Figure 2, Items 13 and 16) and plate (Figure 2, Item 4) with screw (Figure 2, Item 17). Install cover (Figure 2, Item 14) on load center (Figure 2, Item 9) with six screws (Figure 2, Item 15). Connect plug (Figure 2, Item 2) to air conditioner (Figure 2, Item 3). Install 12 clamps (Figure 2, Item 22) on wiring harness (Figure 2, Item 23) and van ceiling (Figure 2, Item 1) with 12 screws (Figure 2, Item 21).
4. 5. 6. 7.
0654-4
TM 9-2320-272-23-4
0654
23 22 21 3 8 19 18 17 16 15 5 6 20 4
7 14 9 13 12 10 11
M4045DAA
Figure 2. Van Air Conditioner Wiring Harness Installation. END OF TASK 0654-5
TM 9-2320-272-23-4
0654
FOLLOW-ON MAINTENANCE 1. 2. Install ceiling filler and side panels. Connect battery ground cables. (Volume 2, WP 0350)
0654-6
TM 9-2320-272-23-4
0655
FIELD MAINTENANCE VAN HEATER WIRING HARNESS REPLACEMENT
0655-1
TM 9-2320-272-23-4
0655
REMOVAL
NOTE
Tag wires for installation. 1. 2. 3. Remove 12 screws (Figure 1, Item 6) and clamps (Figure 1, Item 7) from van ceiling (Figure 1, Item 1) and wiring harness (Figure 1, Item 5). Remove two grommets (Figure 1, Item 3) from van ceiling (Figure 1, Item 1) and wiring harness (Figure 1, Item 5). Disconnect two plugs (Figure 1, Item 2) from heater (Figure 1, Item 4).
0655-2
TM 9-2320-272-23-4
0655
REMOVAL - Continued
7 6 5 4
M4046DAA
Figure 1.
Van Heater Wiring Harness Removal.
0655-3
TM 9-2320-272-23-4
0655
REMOVAL - Continued 4. 5. 6. 7. 8. 9. 10. 11. Remove thermostat cover (Figure 2, Item 5) from thermostat (Figure 2, Item 6). Remove four screws (Figure 2, Item 4) and thermostat (Figure 2, Item 6) from control center box (Figure 2, Item 18). Remove two screws (Figure 2, Item 2) and wires (Figure 2, Item 3) from control center box (Figure 2, Item 18). Remove four screws (Figure 2, Item 7) and upper cover (Figure 2, Item 1) from control center box (Figure 2, Item 18). Remove six screws (Figure 2, Item 14) and cover (Figure 2, Item 13) from load center (Figure 2, Item 9). Remove screw (Figure 2, Item 16) and clamp (Figure 2, Item 17) from wiring harnesses (Figure 2, Item 15). Remove setscrew (Figure 2, Item 11), screw (Figure 2, Item 10), and two wires (Figure 2, Item 12) from load center (Figure 2, Item 9). Remove wiring harnesses (Figure 2, Item 15) from van body (Figure 2, Item 8).
0655-4
TM 9-2320-272-23-4
0655
REMOVAL - Continued
1 3 2 4 5
6 7
18 8
16 15 17
14
12 11
13 10
M4047DAA
Van Heater Wiring Harness Removal.
0655-5
TM 9-2320-272-23-4
0655
INSTALLATION 1. Position wiring harness (Figure 3, Item 15) on van body (Figure 3, Item 8) and install two wires (Figure 3, Item 12) on load center (Figure 3, Item 9) with screw (Figure 3, Item 10) and setscrew (Figure 3, Item 11). Place clamp (Figure 3, Item 17) on wiring harnesses (Figure 3, Item 15) and install on load center (Figure 3, Item 9) with screw (Figure 3, Item 16). Install cover (Figure 3, Item 13) on load center (Figure 3, Item 9) with six screws (Figure 3, Item 14). Install upper cover (Figure 3, Item 1) on center control box (Figure 3, Item 18) with four screws (Figure 3, Item 7). Install two wires (Figure 3, Item 3) on thermostat (Figure 3, Item 6) with two screws (Figure 3, Item 2). Install thermostat (Figure 3, Item 6) on upper cover (Figure 3, Item 1) with two screws (Figure 3, Item 4). Install thermostat cover (Figure 3, Item 5) on thermostat (Figure 3, Item 6).
2. 3. 4. 5. 6. 7.
0655-6
TM 9-2320-272-23-4
0655
1 3 2 4 5
6 7
18 8
16 15 17
14
12 11
13 10
M4048DAA
Figure 3.
Van Heater Wiring Harness Installation.
0655-7
TM 9-2320-272-23-4
0655
INSTALLATION - Continued 8. 9. 10. Connect two plugs (Figure 4, Item 2) to heater (Figure 4, Item 4). Install two grommets (Figure 4, Item 3) on wiring harness (Figure 4, Item 5) and van ceiling (Figure 4, Item 1). Install 12 clamps (Figure 4, Item 7) on wiring harness (Figure 4, Item 5) and van ceiling (Figure 4, Item 1) with 12 screws (Figure 4, Item 6).
7 6 5 4
M4049DAA
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install ceiling filler and side panels.
Van Heater Wiring Harness Installation.
Connect battery ground cables. (Volume 2, WP 0350)
0655-8
TM 9-2320-272-23-4
0656
FIELD MAINTENANCE ELECTRIC HEATER (10 KW) WIRING HARNESS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Tool Kit, Electrical Contact (Volume 5, WP 0826, Table 1, Item 55) Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Battery ground cables disconnected. (Volume 2, WP 0350) Ceiling filler and side panels removed.
0656-1
TM 9-2320-272-23-4
0656
REMOVAL
NOTE
Tag wires for installation. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Remove 12 screws (Figure 1, Item 12) and clamps (Figure 1, Item 11) from van ceiling (Figure 1, Item 26) and wiring harness (Figure 1, Item 10). Remove grommet (Figure 1, Item 15) from van ceiling (Figure 1, Item 26) and wiring harness (Figure 1, Item 10). Remove wires (Figure 1, Item 15) and (Figure 1, Item 16) from heater (Figure 1, Item 14). Remove thermostat cover (Figure 1, Item 4) from thermostat (Figure 1, Item 19). Remove two screws (Figure 1, Item 3) and thermostat (Figure 1, Item 19) from upper cover (Figure 1, Item 28). Remove three insulated wire splicers (Figure 1, Item 18) from wiring harness (Figure 1, Item 20) and thermostat leads (Figure 1, Item 2). Discard insulated wire splicers. Remove four screws (Figure 1, Item 1) and upper cover (Figure 1, Item 28) from control center box (Figure 1, Item 17). Remove six screws (Figure 1, Item 29) and cover (Figure 1, Item 30) from load center (Figure 1, Item 18). Remove screw (Figure 1, Item 5), clamp (Figure 1, Item 6), and wiring harnesses (Figure 1, Item 21) and (Figure 1, Item 20) from load center (Figure 1, Item 8). Remove screw (Figure 1, Item 22) and wire (Figure 1, Item 23) from neutral bus (Figure 1, Item 7). Remove three screws (Figure 1, Item 25) and wires (Figure 1, Item 24) from 20 amp circuit breakers (Figure 1, Item 9). Remove wiring harness (Figure 1, Item 20) from van body (Figure 1, Item 27).
0656-2
TM 9-2320-272-23-4
0656
REMOVAL - Continued
3 1 2
19 18 20
7 21 29 17 20 28 30 9 27 24 25 26 22 23 8
16 15
10
11 12 13 14
Figure 1. Electric Heater (10 Kw) Wiring Harness Removal. END OF TASK
M4055DAA
0656-3
TM 9-2320-272-23-4
0656
INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Position wiring harness (Figure 2, Item 20) on van body (Figure 2, Item 27). Install three wires (Figure 2, Item 24) on 20 amp circuit breakers (Figure 2, Item 9) with three screws (Figure 2, Item 25). Install wire (Figure 2, Item 23) on neutral bus (Figure 2, Item 7) with screw (Figure 2, Item 22). Install clamp (Figure 2, Item 6) on wiring harnesses (Figure 2, Item 20) and (Figure 2, Item 21) and load center (Figure 2, Item 8) with screw (Figure 2, Item 5). Install cover (Figure 2, Item 30) on load center (Figure 2, Item 3) with six screws (Figure 2, Item 29). Install upper cover (Figure 2, Item 28) on control center box (Figure 2, Item 17) with four screws (Figure 2, Item 1). Connect thermostat leads (Figure 2, Item 2) to wiring harness (Figure 2, Item 20) with three insulated wire splicers (Figure 2, Item 18). Install thermostat (Figure 2, Item 19) on upper cover (Figure 2, Item 28) with two screws (Figure 2, Item 3). Install thermostat cover (Figure 2, Item 4) on thermostat (Figure 2, Item 19). Install wires (Figure 2, Item 19) and (Figure 2, Item 13) on heater (Figure 2, Item 14). Install grommet (Figure 2, Item 15) on wiring harness (Figure 2, Item 10) and van ceiling (Figure 2, Item 26). Install 12 clamps (Figure 2, Item 11) on wiring harness (Figure 2, Item 10) and van ceiling (Figure 2, Item 26) with 12 screws (Figure 2, Item 12).
0656-4
TM 9-2320-272-23-4
0656
3 1 2
19 18 20
7 21 29 17 20 28 30 9 27 24 25 26 22 23 8
16 15
10
11 12 13 14
Figure 2. Electric Heater (10 Kw) Wiring Harness Installation. END OF TASK
M4056DAA
0656-5
TM 9-2320-272-23-4
0656
0656-6
TM 9-2320-272-23-4
0657
FIELD MAINTENANCE BLACKOUT BYPASS WIRING HARNESS REPAIR
0657-1
TM 9-2320-272-23-4
0657
REMOVAL
NOTE
Tag wires for installation. 1. 2. 3. 4. 5. 6. 7. Remove six screws (Figure 1, Item 1) and cover (Figure 1, Item 2) from load center (Figure 1, Item 6). Remove two setscrews (Figure 1, Item 16) and wires (Figure 1, Item 3) from 3-pole circuit breaker (Figure 1, Item 5). Remove screw (Figure 1, Item 15) and wire (Figure 1, Item 11) from 30 amp circuit breaker (Figure 1, Item 7). Remove two screws (Figure 1, Item 8) and cover (Figure 1, Item 9) from switch (Figure 1, Item 13). Remove two screws (Figure 1, Item 14) and switch (Figure 1, Item 13) from van body (Figure 1, Item 12). Loosen three screws (Figure 1, Item 10) and remove wires (Figure 1, Item 3) from switch (Figure 1, Item 13). Remove wiring harness (Figure 1, Item 4) from van body (Figure 1, Item 12).
0657-2
TM 9-2320-272-23-4
0657
REMOVAL - Continued
2 1 3 4
5 16 6
7 11 15
8 14 13
9 3 10 4 12 11
M4057DAA
Blackout Bypass Wiring Harness Removal.
0657-3
TM 9-2320-272-23-4
0657
REPAIR For wiring harness repair, refer to (Volume 3, WP 0352). END OF TASK INSTALLATION 1. 2. 3. 4. 5. 6. 7. Position wiring harness (Figure 2, Item 4) on van body (Figure 2, Item 12). Install three wires (Figure 2, Item 3) on switch (Figure 2, Item 13) and tighten three screws (Figure 2, Item 10). Install switch (Figure 2, Item 15) on van body (Figure 2, Item 12) with two screws (Figure 2, Item 14). Install cover (Figure 2, Item 9) on switch (Figure 2, Item 13) with two screws (Figure 2, Item 8). Install wire (Figure 2, Item 11) on 30 amp circuit breaker (Figure 2, Item 7) with screw (Figure 2, Item 15). Install two wires (Figure 2, Item 3) on 3-pole circuit breaker (Figure 2, Item 5) with two setscrews (Figure 2, Item 16). Install cover (Figure 2, Item 2) on load center (Figure 2, Item 6) with six screws (Figure 2, Item 1).
0657-4
TM 9-2320-272-23-4
0657
2 1 3 4
5 16 6
7 11 15
8 14 13
9 3 10 4 12 11
M4058DAA
Figure 2. Blackout Bypass Wiring Harness Installation. END OF TASK
0657-5
TM 9-2320-272-23-4
0657
0657-6
TM 9-2320-272-23-4
0658
FIELD MAINTENANCE EMERGENCY LAMP WIRING HARNESS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 289) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Battery ground cables disconnected. (Volume 2, WP 0350) Ceiling filter and side panels removed.
0658-1
TM 9-2320-272-23-4
0658
REMOVAL
NOTE
Tag wires for installation. 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove 12 screws (Figure 1, Item 6) and clamps (Figure 1, Item 5) from van ceiling (Figure 1, Item 3) and wiring harness (Figure 1, Item 4). Remove two screws (Figure 1, Item 13) and cover (Figure 1, Item 12) from switch (Figure 1, Item 15). Remove two screws (Figure 1, Item 14) and switch (Figure 1, Item 15) from switch box (Figure 1, Item 17). Disconnect two wires (Figure 1, Item 11) and wire (Figure 1, Item 16) from switch (Figure 1, Item 15). Remove four screws (Figure 1, Item 10) and box (Figure 1, Item 17) from van wall (Figure 1, Item 12). Remove grommet (Figure 1, Item 1) from switch box (Figure 1, Item 17). Disconnect emergency lamp wiring harness lead (Figure 1, Item 18) from emergency lamp wiring harness lead (Figure 1, Item 9). Remove 12 screws (Figure 1, Item 6) and clamps (Figure 1, Item 5) from wiring harness (Figure 1, Item 8) in van ceiling (Figure 1, Item 3). Remove grommet (Figure 1, Item 7) and wiring harness (Figure 1, Item 8) from van ceiling (Figure 1, Item 3).
0658-2
TM 9-2320-272-23-4
0658
REMOVAL - Continued
1 12 11 10
3 4 5 6 13
14 16 17 18 9 15
3 7
8 3
5 6
M4059DAA
Figure 1.
Emergency Lamp Wiring Harness Removal. 0658-3

TM 9-2320-272-23-4
0658
REMOVAL - Continued 10. 11. 12. 13. 14. Disconnect lead (Figure 2, Item 2) from circuit breaker (Figure 2, Item 1). Remove two screws (Figure 2, Item 5) and clamps (Figure 2, Item 4) from wiring harness (Figure 2, Item 3) and van body (Figure 2, Item 12). Remove two screws (Figure 2, Item 3) and clamps (Figure 2, Item 6) from wiring harness (Figure 2, Item 3) and van body (Figure 2, Item 12). Remove locknut (Figure 2, Item 8), screw (Figure 2, Item 15), clamp (Figure 2, Item 14), and wiring harness (Figure 2, Item 3) from spare tire carrier bracket (Figure 2, Item 7). Discard locknut. Remove nut (Figure 2, Item 11) and wire (Figure 2, Item 10) from positive battery terminal (Figure 2, Item 9).
0658-4
TM 9-2320-272-23-4
0658
REMOVAL - Continued
4 5 1 2
12
6 13
11
15 14
10
M4060DAA
Figure 2. Emergency Wiring Harness Removal. END OF TASK 0658-5

TM 9-2320-272-23-4
0658
INSTALLATION 1. 2. 3. 4. 5. Install wire (Figure 3, Item 10) on positive battery terminal (Figure 3, Item 9) with nut (Figure 3, Item 11). Install wiring harness (Figure 3, Item 3) on spare tire carrier bracket (Figure 3, Item 7) with clamp (Figure 3, Item 14), screw (Figure 3, Item 15), and locknut (Figure 3, Item 8). Install two clamps (Figure 3, Item 6) on wiring harness (Figure 3, Item 3) and van body (Figure 3, Item 12) with two screws (Figure 3, Item 13). Install two clamps (Figure 3, Item 14) on wiring harness (Figure 3, Item 3) and van body (Figure 3, Item 12) with two screws (Figure 3, Item 5). Connect lead (Figure 3, Item 2) to circuit breaker (Figure 3, Item 1).
0658-6
TM 9-2320-272-23-4
0658
4 5 1 2
12
6 13
11
15
14
10
M4061DAA
Figure 3. Emergency Lamp Wiring Harness Installation.
0658-7
TM 9-2320-272-23-4
0658
INSTALLATION - Continued 6. 7. Install grommet (Figure 4, Item 3) on van ceiling (Figure 4, Item 1) and wiring harness (Figure 4, Item 2). Install 12 clamps (Figure 4, Item 5) on van ceiling (Figure 4, Item 1) and wiring harness (Figure 4, Item 2) with 12 screws (Figure 4, Item 4).
0658-8
TM 9-2320-272-23-4
0658
5 4
3 2
M4062DAA
Figure 4. Emergency Lamp Wiring Harness Installation.
0658-9
TM 9-2320-272-23-4
0658
INSTALLATION - Continued 8. 9. 10. 11. 12. 13. 14. Connect emergency lamp wiring harness (Figure 5, Item 14) to emergency lamp wiring harness lead. Install grommet (Figure 5, Item 1) on switch box (Figure 5, Item 13). Install two cables (Figure 5, Item 11) and cable (Figure 5, Item 12) on switch (Figure 5, Item 6). Install switch box (Figure 5, Item 13) on van wall (Figure 5, Item 2) with four screws (Figure 5, Item 10). Install switch (Figure 5, Item 6) on switch box (Figure 5, Item 13) with two screws (Figure 5, Item 5). Install cover (Figure 5, Item 4) on switch (Figure 5, Item 6) with two screws (Figure 5, Item 3). Install emergency lamp wiring harness (Figure 5, Item 9) on van ceiling (Figure 5, Item 16) with 12 clamps (Figure 5, Item 7) and screws (Figure 5, Item 8).
0658-10
TM 9-2320-272-23-4
0658
2
1 11 10 3
5 6 12 13 14 15
16
7 9
M4063DAA
Figure 5. Emergency Lamp Wiring Harness Installation. END OF TASK
0658-11
TM 9-2320-272-23-4
0658
0658-12
TM 9-2320-272-23-4
0659
FIELD MAINTENANCE BLACKOUT AND CLEARANCE LIGHTS WIRING HARNESS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Main power switch off. (TM 9-2320-272-10) Clearance and blackout marker lights removed. (WP 0644) Equipment Condition (cont.) Rear wall interior panels removed. Ceiling filler and side panels removed. Ceiling air ducts removed. Battery ground cables disconnected. (Volume 2, WP 0350)
0659-1
TM 9-2320-272-23-4
0659
REMOVAL
NOTE
Tag wires for installation. 1. 2. 3. 4. 5. 6. 7. Remove grommet (Figure 1, Item 2) from van body (Figure 1, Item 3) and wiring harness (Figure 1, Item 1). Remove two screws (Figure 1, Item 13) and clamps (Figure 1, Item 14) from van body (Figure 1, Item 3) and wiring harness (Figure 1, Item 1). Disconnect two wiring harness connectors (Figure 1, Item 4) from rear wiring harness connectors (Figure 1, Item 5). Remove 12 screws (Figure 1, Item 10) and clamps (Figure 1, Item 11) from van ceiling (Figure 1, Item 12) and wiring harness (Figure 1, Item 1). Remove five screws (Figure 1, Item 8) and clamps (Figure 1, Item 9) from van ceiling (Figure 1, Item 12) and wiring harness (Figure 1, Item 1). Remove four grommets (Figure 1, Item 6) from van ceiling (Figure 1, Item 12) and wiring harness (Figure 1, Item 1). Remove wiring harness (Figure 1, Item 1) from van body (Figure 1, Item 7).
0659-2
TM 9-2320-272-23-4
0659
REMOVAL - Continued
1 2
14 6 10
13
11 12
1 7
M4064DAA
Blackout and Clearance Lights Wiring Harness Removal.
0659-3
TM 9-2320-272-23-4
0659
INSTALLATION 1. 2. 3. 4. 5. 6. Position wiring harness (Figure 2, Item 1) on van body (Figure 2, Item 7) and install four grommets (Figure 2, Item 6) on van ceiling (Figure 2, Item 12) and wiring harness (Figure 2, Item 1). Install five clamps (Figure 2, Item 9) on van ceiling (Figure 2, Item 12) and wiring harness (Figure 2, Item 1) with five screws (Figure 2, Item 8). Install 12 clamps (Figure 2, Item 11) on van ceiling (Figure 2, Item 12) and wiring harness (Figure 2, Item 1) with 12 screws (Figure 2, Item 10). Connect two wiring harness connectors (Figure 2, Item 4) to rear wiring harness connectors (Figure 2, Item 5). Install two clamps (Figure 2, Item 14) on wiring harness (Figure 2, Item 1) and van body (Figure 2, Item 3) with two screws (Figure 2, Item 13). Install grommet (Figure 2, Item 2) on wiring harness (Figure 2, Item 1) and van body (Figure 2, Item 3).
0659-4
TM 9-2320-272-23-4
0659
14 6 10
13
11 12
1 7
M4065DAA
Blackout and Clearance Lights Wiring Harness Installation.
0659-5
TM 9-2320-272-23-4
0659
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Install ceiling air ducts. Install ceiling filler and side panels. Install clearance and blackout marker lights. (WP 0644) Install rear wall interior panels. Connect battery ground cables. (Volume 2, WP 0350) Main power switch on. (TM 9-2320-272-10)
0659-6
TM 9-2320-272-23-4
0660
FIELD MAINTENANCE 400 HZ SUPPLY WIRING HARNESS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Sealing Compound (Volume 5, WP 0825, Table 1, Item 57) Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Battery ground cables disconnected. (Volume 2, WP 0350) Ceiling filler and side panels removed.
0660-1
TM 9-2320-272-23-4
0660
REMOVAL
NOTE
Tag wires for installation. 1. 2. 3. 4. Remove four screws (Figure 1, Item 1) and upper cover (Figure 1, Item 2) from control center box (Figure 1, Item 10). Remove four screws (Figure 1, Item 5) and lower cover (Figure 1, Item 4) from control center box (Figure 1, Item 10). Remove screw (Figure 1, Item 11) and wire (Figure 1, Item 8) from terminal (Figure 1, Item 9). Remove three screws (Figure 1, Item 3) and wires (Figure 1, Item 7) from circuit breaker (Figure 1, Item 6).
0660-2
TM 9-2320-272-23-4
0660
REMOVAL - Continued
1
10
11 3
M4066DAA
Figure 1.
400 Hz Supply Wiring Harness Removal.
0660-3
TM 9-2320-272-23-4
0660
REMOVAL - Continued 5. 6. 7. 8. 9. 10. Disconnect cables (Figure 2, Items 12 and 13) from connectors (Figure 2, Items 6 and 10). Remove eight screws (Figure 2, Item 11) and electrical connector box cover (Figure 2, Item 7) from electrical connector box (Figure 2, Item 9). Disconnect four wires (Figure 2, Item 8) from connector (Figure 2, Item 6). Remove six screws (Figure 2, Item 15) and cover (Figure 2, Item 16) from load center (Figure 2, Item 4). Remove screw (Figure 2, Item 1) and clamp (Figure 2, Item 2) from harness (Figure 2, Item 3), harness (Figure 2, Item 14), and load center (Figure 2, Item 4). Pull wiring harness (Figure 2, Item 14) out of coupling (Figure 2, Item 5) and remove from load center (Figure 2, Item 4) and electrical connector box (Figure 2, Item 9).
0660-4
TM 9-2320-272-23-4
0660
REMOVAL - Continued
16
15
14 5
8 11 10 12 13
M4067DAA
400 Hz Wiring Harness Removal.
0660-5
TM 9-2320-272-23-4
0660
INSTALLATION 1. 2. 3. 4. 5. 6. Push wiring harness (Figure 3, Item 14) through coupling (Figure 3, Item 5), electrical connector box (Figure 3, Item 9), and load center (Figure 3, Item 4). Connect four wires (Figure 3, Item 8) to connector (Figure 3, Item 6). Install clamp (Figure 3, Item 2) on harness (Figure 3, Item 3), harness (Figure 3, Item 14), and load center (Figure 3, Item 4) with screw (Figure 3, Item 1). Install cover (Figure 3, Item 16) on load center (Figure 3, Item 4) with six screws (Figure 3, Item 15). Apply sealing compound to screws (Figure 3, Item 11) and install electrical connector box cover (Figure 3, Item 7) on electrical connector box (Figure 3, Item 9) with eight screws (Figure 3, Item 11). Connect cables (Figure 3, Items 12 and 13) to connectors (Figure 3, Items 6 and 10).
0660-6
TM 9-2320-272-23-4
0660
16
15
14 5
8 11 10 12 13
M4068DAA
Figure 3. 400 Hz Supply Wiring Harness Installation.
0660-7
TM 9-2320-272-23-4
0660
INSTALLATION - Continued 7. 8. 9. 10. Install three wires (Figure 4, Item 7) on circuit breaker (Figure 4, Item 6) with three screws (Figure 4, Item 3). Install wire (Figure 4, Item 8) on terminal (Figure 4, Item 9) with screw (Figure 4, Item 11). Install lower cover (Figure 4, Item 4) on control center box (Figure 4, Item 10) with four screws (Figure 4, Item 5). Install upper cover (Figure 4, Item 2) on control center box (Figure 4, Item 10) with four screws (Figure 4, Item 1).
0660-8
TM 9-2320-272-23-4
0660
1
10
11 3
M4069DAA
400 Hz Supply Wiring Harness Removal.
0660-9
TM 9-2320-272-23-4
0660
0660-10
TM 9-2320-272-23-4
0661
FIELD MAINTENANCE BRANCHED 400 HZ RECEPTACLE WIRING HARNESS REPLACEMENT
0661-1
TM 9-2320-272-23-4
0661
REMOVAL
NOTE
Tag wires for installation. 1. 2. Remove four screws (Figure 1, Item 1) and upper cover (Figure 1, Item 2) from control center box (Figure 1, Item 6). Remove two screws (Figure 1, Item 3) and wires (Figure 1, Item 4) from terminal (Figure 1, Item 5).
1
5 3
M10224DAA
Figure 1.
Branched 400 Hz Receptacle Wiring Harness Removal.
0661-2
TM 9-2320-272-23-4
0661
REMOVAL - Continued 3. Remove six screws (Figure 2, Item 4) and clamps (Figure 2, Item 3) from branched 400 Hz receptacle harness (Figure 2, Item 2) and van ceiling (Figure 2, Item 1).
3 4
M4070DAA
Branched 400 Hz Receptacle Wiring Harness Removal.
0661-3
TM 9-2320-272-23-4
0661
INSTALLATION 1. Install 400 Hz branched receptacle harness (Figure 3, Item 2) on van ceiling (Figure 3, Item 1) with six clamps (Figure 3, Item 3) and screws (Figure 3, Item 4).
3 4
M4071DAA
Figure 3. Branched 400 Hz Receptacle Wiring Harness Installation.
0661-4
TM 9-2320-272-23-4
0661
INSTALLATION - Continued 2. 3. Install two wires (Figure 4, Item 4) on terminal (Figure 4, Item 5) with two screws (Figure 4, Item 3). Install upper cover (Figure 4, Item 2) on control center box (Figure 4, Item 6) with four screws (Figure 4, Item 1).
1
5 3
M10225DAA
Figure 4. Branched 400 Hz Receptacle Wiring Harness Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install ceiling filler and side panels. Connect battery ground cables. (Volume 2, WP 0350)
0661-5/6 blank
TM 9-2320-272-23-4
0662
FIELD MAINTENANCE TELEPHONE POST WIRING HARNESS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Inside telephone jacks removed. (WP 0626)
0662-1
TM 9-2320-272-23-4
0662
REMOVAL
NOTE
Tag wires for installation. 1. 2. Remove six screws (Figure 1, Item 4) and clamps (Figure 1, Item 3) from wiring harness (Figure 1, Item 2) and van ceiling (Figure 1, Item 1). Remove wiring harness (Figure 1, Item 2) from van body (Figure 1, Item 5).
3 4
M4074DAA
Figure 1. Telephone Post Wiring Harness Removal. END OF TASK
0662-2
TM 9-2320-272-23-4
0662
INSTALLATION 1. 2. Install wiring harness (Figure 2, Item 2) on van body (Figure 2, Item 5). Install wiring harness (Figure 2, Item 2) on van ceiling (Figure 2, Item 1) with six clamps (Figure 2, Item 3) and screws (Figure 2, Item 4).
3 4
M4075DAA
Figure 2. Telephone Post Wiring Harness Installation. END OF TASK
0662-3
TM 9-2320-272-23-4
0662
FOLLOW-ON MAINTENANCE Install inside telephone jacks. (WP 0626) END OF TASK END OF WORK PACKAGE
0662-4
TM 9-2320-272-23-4
0663
FIELD MAINTENANCE 3 PHASE RECEPTACLE WIRING HARNESS REPLACEMENT
0663-1
TM 9-2320-272-23-4
0663
REMOVAL
NOTE
Tag wires for installation. 1. 2. 3. 4. 5. 6. Remove six screws (Figure 1, Item 1) and cover (Figure 1, Item 12) from load center (Figure 1, Item 5). Remove screw (Figure 1, Item 3) and clamp (Figure 1, Item 13) from wiring harness (Figure 1, Item 2) and van body (Figure 1, Item 4). Remove screw (Figure 1, Item 8) and wire (Figure 1, Item 6) from neutral bus (Figure 1, Item 7). Remove three screws (Figure 1, Item 10) and wires (Figure 1, Item 11) from circuit breakers (Figure 1, Item 9). Remove 12 screws (Figure 1, Item 16) and clamps (Figure 1, Item 15) from van ceiling (Figure 1, Item 14) and wiring harness (Figure 1, Item 2). Remove wiring harness (Figure 1, Item 2) from van body (Figure 1, Item 4).
0663-2
TM 9-2320-272-23-4
0663
REMOVAL - Continued
4
5 6 1 2 13 3 7
12 8 9
11 10
14
15 16
M10351DAA
3 Phase Receptacle Wiring Harness Removal.
0663-3
TM 9-2320-272-23-4
0663
INSTALLATION 1. 2. 3. 4. 5. 6. Position wiring harness (Figure 2, Item 2) on van body (Figure 2, Item 4). Install wiring harness (Figure 2, Item 2) on van ceiling (Figure 2, Item 14) with 12 clamps (Figure 2, Item 15) and screws (Figure 2, Item 16). Install three wires (Figure 2, Item 11) on circuit breakers (Figure 2, Item 9) with three screws (Figure 2, Item 10). Install wire (Figure 2, Item 6) on neutral bus (Figure 2, Item 7) with screw (Figure 2, Item 8). Install clamp (Figure 2, Item 13) on wiring harness (Figure 2, Item 2) and van body (Figure 2, Item 4) with screw (Figure 2, Item 3). Install cover (Figure 2, Item 12) on load center (Figure 2, Item 5) with six screws (Figure 2, Item 1).
0663-4
TM 9-2320-272-23-4
0663
4
5 6 1 2 13 3 7
12 8 9
11 10
14
15 16
M10352DAA
3 Phase Receptacle Wiring Harness Removal.
0663-5
TM 9-2320-272-23-4
0663
0663-6
TM 9-2320-272-23-4
0664
FIELD MAINTENANCE FORWARD DECK PLATE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Lockwasher (Volume 5, WP 0827, Table 1, Item 62) Qty: 6 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10)
0664-1
TM 9-2320-272-23-4
0664
REMOVAL Remove six screws (Figure 1, Item 2), lockwashers (Figure 1, Item 3), washers (Figure 1, Item 4), and deck plate (Figure 1, Item 1) from wrecker body (Figure 1, Item 5). Discard lockwashers.
3 4
M10010DAA
Figure 1. Forward Deck Plate Removal. END OF TASK
0664-2
TM 9-2320-272-23-4
0664
INSTALLATION Install deck plate (Figure 2, Item 1) on wrecker body (Figure 2, Item 5) with six washers (Figure 2, Item 4), lockwashers (Figure 2, Item 3), and screws (Figure 2, Item 2).
3 4
M10011DAA
Forward Deck Plate Installation.
0664-3/4 blank
TM 9-2320-272-23-4
0665
FIELD MAINTENANCE CRANE BODY HOUSING ASSEMBLY COVER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Lockwasher Materials/Parts (cont.) (Volume 5, WP 0827, Table 1, Item 186) Qty: 9 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0665-1
TM 9-2320-272-23-4
0665
REMOVAL 1. 2. Remove nine screws (Figure 1, Item 1), lockwashers (Figure 1, Item 3), washers (Figure 1, Item 4), and bracket (Figure 1, Item 5), from crane body housing assembly cover (Figure 1, Item 2). Discard lockwashers. Remove crane body housing assembly cover (Figure 1, Item 2) from crane body (Figure 1, Item 6).
3 4
3 4
6
M5264DAA
Figure 1. Crane Body Housing Assembly Cover Removal. END OF TASK
0665-2
TM 9-2320-272-23-4
0665
INSTALLATION 1. 2. Place crane body housing assembly cover (Figure 2, Item 2) on crane body (Figure 2, Item 6). Install crane body housing assembly cover (Figure 2, Item 2) to crane body (Figure 2, Item 6) with nine screws (Figure 2, Item 1), lockwashers (Figure 2, Item 3), washers (Figure 2, Item 4), and bracket (Figure 2, Item 5).
3 4
3 4
6
M10031DAA
Crane Body Housing Assembly Cover Installation.
0665-3/4 blank
TM 9-2320-272-23-4
0666
FIELD MAINTENANCE WRECKER BODY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Chain Assembly (2) (Volume 5, WP 0826, Table 1, Item 15) Guide Lines (2) Hoist Assembly Lifting Device Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 315) Qty: 16 Locknut (Volume 5, WP 0827, Table 1, Item 438) Qty: 16 Personnel Required (3) Equipment Condition Parking brake set. (TM 9-2320-272-10) Crane turntable removed. (WP 0692)
0666-1
TM 9-2320-272-23-4
0666
REMOVAL
WARNING
Lifting device must have a weight capacity greater than the combined weight of the truck bed. Failure to comply may result in damage to equipment, injury, or death to personnel. All personnel must stand clear during lifting operations. A snapped cable, or swinging or shifting load, may occur. Failure to comply may result in injury or death to personnel. Solvent cleaning compound is flammable and toxic. Do not use near open flame and always have a fire extinguisher nearby when solvents are used. Use only in wellventilated places, wear protective clothing, and dispose of cleaning rags in approved container. Failure to comply may result in damage to equipment, injury, or death to personnel.
NOTE
The left and right side body mounts are replaced the same. This procedure covers the left side body mounts. 1. 2. 3. 4. Remove four locknuts (Figure 1, Item 12), two U-bolts (Figure 1, Item 11), and wood blocks (Figure 1, Item 3) from frame rail (Figure 1, Item 4) and wrecker body (Figure 1, Item 1). Discard locknuts. Remove four locknuts (Figure 1, Item 14) and two U-bolts (Figure 1, Item 13) from frame rail (Figure 1, Item 4) and wrecker body (Figure 1, Item 1). Discard locknuts. Remove four locknuts (Figure 1, Item 16), two U-bolts (Figure 1, Item 15), and four wood blocks (Figure 1, Item 3) from frame rail (Figure 1, Item 4) and wrecker body (Figure 1, Item 1). Discard locknuts. Remove four locknuts (Figure 1, Item 2), four mounting screws (Figure 1, Item 17), two plates (Figure 1, Item 18), and four wood blocks (Figure 1, Item 3) from frame rail (Figure 1, Item 4) and wrecker body (Figure 1, Item 1). Discard locknuts. Remove 16 locknuts (Figure 1, Item 8), screws (Figure 1, Item 9), and two brackets (Figure 1, Item 10) from frame rail (Figure 1, Item 4). Discard locknuts. Attach two guide lines (Figure 1, Item 5) and utility chains (Figure 1, Item 7) to wrecker body (Figure 1, Item 1) and lifting device (Figure 1, Item 6) to utility chains.
5. 6.
NOTE
Two assistants will help with Steps (7) and (8). 7. 8. Remove wrecker body (Figure 1, Item 1) from frame rail (Figure 1, Item 4) and lower onto support stands. Remove lifting device (Figure 1, Item 6), two chains (Figure 1, Item 7), and guide lines (Figure 1, Item 5) from wrecker body (Figure 1, Item 1).
0666-2
TM 9-2320-272-23-4
0666
REMOVAL - Continued
1 2 6 7 4 18 16 1 5
17
3 15 4 1 1 8 5
14 12 13 11 4 4 3 9
M3030DAA
10
Wrecker Body Removal.
0666-3
TM 9-2320-272-23-4
0666
INSTALLATION 1. 2. 3. 4. 5. 6. Attach two guide lines (Figure 2, Item 5) and utility chains (Figure 2, Item 7) to wrecker body (Figure 2, Item 1) and lifting device (Figure 2, Item 6) to utility chains. Raise wrecker body (Figure 2, Item 1) from support stands and position on frame rail (Figure 2, Item 4). Ensure mounting holes of frame rail and wrecker body are aligned. Install two wood blocks (Figure 2, Item 3) on frame rail (Figure 2, Item 4) and wrecker body (Figure 2, Item 1) with two U-bolts (Figure 2, Item 11) and four locknuts (Figure 2, Item 12). Install two U-bolts (Figure 2, Item 13) on frame rail (Figure 2, Item 4) and wrecker body (Figure 2, Item 1) with four locknuts (Figure 2, Item 14). Install four wood blocks (Figure 2, Item 3) on frame rail (Figure 2, Item 4) and wrecker body (Figure 2, Item 1) with two U-bolts (Figure 2, Item 15) and four locknuts (Figure 2, Item 16). Install two plates (Figure 2, Item 18) and four wood blocks (Figure 2, Item 3) on frame rail (Figure 2, Item 4) and wrecker body (Figure 2, Item 1) with four mounting screws (Figure 2, Item 17) and locknuts (Figure 2, Item 2). Install two brackets (Figure 2, Item 10) on frame rail (Figure 2, Item 4) with 16 screws (Figure 2, Item 9) and locknuts (Figure 2, Item 8). Remove lifting device (Figure 2, Item 6), two chains (Figure 2, Item 7), and guide lines (Figure 2, Item 5) from wrecker body (Figure 2, Item 1).
7. 8.
0666-4
TM 9-2320-272-23-4
0666
1 2 6 7 4 18 16 1 5
17
3 15 4 1 1 8 5
14 12 13 11 4 4 3 9
M9990DAA
10
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE Install crane turntable. (WP 0692) END OF TASK END OF WORK PACKAGE
Wrecker Body Installation.
0666-5/6 blank
TM 9-2320-272-23-4
0667
FIELD MAINTENANCE FUEL CAN BRACKET REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 283) Qty: 7 Materials/Parts (cont.) Locknut (Volume 5, WP 0827, Table 1, Item 285) Qty: 4 Lockwasher (Volume 5, WP 0827, Table 1, Item 186) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0667-1
TM 9-2320-272-23-4
0667
REMOVAL 1. 2. 3. 4. Remove four screws (Figure 1, Item 1), locknuts (Figure 1, Item 7), and fuel can holder (Figure 1, Item 2) from upper bracket (Figure 1, Item 6). Discard locknuts. Remove two screws (Figure 1, Item 3), washers (Figure 1, Item 5), lockwashers (Figure 1, Item 4), and lower bracket (Figure 1, Item 8) from hydraulic oil filter housing (Figure 1, Item 10). Discard lockwashers. Remove seven locknuts (Figure 1, Item 11) and screws (Figure 1, Item 12) from upper bracket (Figure 1, Item 6) and hydraulic oil reservoir (Figure 1, Item 9). Discard locknuts. Remove brackets (Figure 1, Items 6 and 8) from oil reservoir (Figure 1, Item 9).
0667-2
TM 9-2320-272-23-4
0667
REMOVAL - Continued
2 3
5 12
12
6 7 8 9 11
10
M6046DAA
Fuel Can Bracket Removal.
0667-3
TM 9-2320-272-23-4
0667
INSTALLATION 1. Position lower bracket (Figure 2, Item 8) and upper bracket (Figure 2, Item 6) on hydraulic oil filter housing (Figure 2, Item 10) and install with two lockwashers (Figure 2, Item 4), washers (Figure 2, Item 5), and screws (Figure 2, Item 3). Install bracket (Figure 2, Item 6) on oil reservoir (Figure 2, Item 9) with seven screws (Figure 2, Item 12) and locknuts (Figure 2, Item 11). Install fuel can holder (Figure 2, Item 2) on upper bracket (Figure 2, Item 6) with four screws (Figure 2, Item 1) and locknuts (Figure 2, Item 7).
2. 3.
0667-4
TM 9-2320-272-23-4
0667
1
2 3
5 12
12
6 7 8 9 11
10
M6047DAA
Fuel Can Bracket Installation.
0667-5/6 blank
TM 9-2320-272-23-4
0668
FIELD MAINTENANCE FRONT WINCH REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Chain Assembly (Volume 5, WP 0826, Table 1, Item 15) Lifting Device Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Tape, Antiseizing (Volume 5, WP 0825, Table 1, Item 65) Materials/Parts (cont.) Locknut (Volume 5, WP 0827, Table 1, Item 289) Qty: 6 Lockwasher (Volume 5, WP 0827, Table 1, Item 405) Qty: 8 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Front winch oil drained. (Volume 5, WP 0820) Front bumper removed. (Volume 3, WP 0516) Front winch cable removed. (WP 0684)
0668-1
TM 9-2320-272-23-4
0668
REMOVAL
CAUTION
When disconnecting hydraulic lines and hoses, plug all openings to prevent dirt from entering and causing damage to internal parts.
NOTE
Have drainage container ready to catch oil. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. Tag all hydraulic lines for installation. 1. 2. 3. Disconnect oil supply hose (Figure 1, Item 26) from rear elbow (Figure 1, Item 27) on winch motor (Figure 1, Item 28). Disconnect oil return hose (Figure 1, Item 25) from front elbow (Figure 1, Item 24) on winch motor (Figure 1, Item 28). Remove four screws (Figure 1, Item 2), lockwashers (Figure 1, Item 3), and washers (Figure 1, Item 4) from left mounting support plate (Figure 1, Item 5) and left frame rail extension (Figure 1, Item 11). Discard lockwashers. Remove three locknuts (Figure 1, Item 12), screws (Figure 1, Item 8), and washers (Figure 1, Item 9) from left inner support plate bracket (Figure 1, Item 10) and left mounting support plate (Figure 1, Item 5). Discard locknuts. Remove four screws (Figure 1, Item 1), lockwashers (Figure 1, Item 23), and washers (Figure 1, Item 22) from right mounting support plate (Figure 1, Item 21) and right frame rail extension (Figure 1, Item 15). Discard lockwashers. Remove three locknuts (Figure 1, Item 13), screws (Figure 1, Item 17), and washers (Figure 1, Item 16) from right inner support plate bracket (Figure 1, Item 14) and right mounting support plate (Figure 1, Item 21). Discard locknuts. Position chains on front winch (Figure 1, Item 18) and attach to lifting device.
4.
5.
6.
7.
WARNING
All personnel must stand clear during lifting operations. A snapped chain, or shifting or swinging load, may result in injury to personnel. Failure to comply may result in injury or death to personnel. 8. 9. 10. With the aid of an assistant, remove front winch (Figure 1, Item 18) from frame rail extensions (Figure 1, Items 11 and 15). Remove four screws (Figure 1, Item 7), washers (Figure 1, Item 6), and left mounting support plate (Figure 1, Item 5) from front winch (Figure 1, Item 18). Remove four screws (Figure 1, Item 20), washers (Figure 1, Item 19), and right mounting support plate (Figure 1, Item 21) from front winch (Figure 1, Item 18).
0668-2
TM 9-2320-272-23-4
0668
REMOVAL - Continued
NOTE
Perform Step (11) if replacing front winch. 11. 12. Install four washers (Figure 1, Items 6 and 19) and screws (Figure 1, Items 7 and 20) on front winch (Figure 1, Item 18). Lower front winch (Figure 1, Item 18) and remove chains and lifting device.
1 23 2 22 21 3 4 5 6 19 7 18 18 17 16 15 14 13 12 11 10
M5250DAA
24
25
20
28
27
26
8 9
Front Winch Removal.
0668-3
TM 9-2320-272-23-4
0668
INSTALLATION
NOTE
Perform Step (1) if installing new front winch. 1. 2. 3. 4. Remove four screws (Figure 2, Items 7 and 20) and washers (Figure 2, Items 6 and 19) from front winch (Figure 2, Item 18). Install right mounting support plate (Figure 2, Item 21) on front winch (Figure 2, Item 18) with four washers (Figure 2, Item 19) and screws (Figure 2, Item 20). Install left mounting support plate (Figure 2, Item 5) on front winch (Figure 2, Item 18) with four washers (Figure 2, Item 6) and screws (Figure 2, Item 7). Position chains on front winch (Figure 2, Item 18) and attach to lifting device.
WARNING
All personnel must stand clear during lifting operations. A snapped chain, or shifting or swinging load, may result in injury to personnel. Failure to comply may result in injury or death to personnel. 5. 6. 7. 8. 9. 10. With the aid of assistant, position front winch (Figure 2, Item 18) on frame rails extensions (Figure 2, Items 11 and 15). Do not remove chains or lifting device until front winch is secured. Install right mounting support plate (Figure 2, Item 21) on right inner support plate (Figure 2, Item 14) with three washers (Figure 2, Item 16), screws (Figure 2, Item 17), and locknuts (Figure 2, Item 13). Install right mounting support plate (Figure 2, Item 21) on right frame rail extension (Figure 2, Item 15) with four washers (Figure 2, Item 22), lockwashers (Figure 2, Item 23), and screws (Figure 2, Item 1). Install left mounting support plate (Figure 2, Item 5) on left inner support plate (Figure 2, Item 10) with three washers (Figure 2, Item 9), screws (Figure 2, Item 8), and locknuts (Figure 2, Item 12). Install left mounting support plate (Figure 2, Item 5) on left frame rail extension (Figure 2, Item 11) with four washers (Figure 2, Item 4), lockwashers (Figure 2, Item 3), and screws (Figure 2, Item 2). Remove lifting device and chains from front winch (Figure 2, Item 18).
NOTE
Wrap all male threads with antiseize tape before installation. 11. 12. Connect oil supply hose (Figure 2, Item 26) to rear elbow (Figure 2, Item 27) on winch motor (Figure 2, Item 28). Connect oil return hose (Figure 2, Item 25) to front elbow (Figure 2, Item 24) on winch motor (Figure 2, Item 28).
0668-4
TM 9-2320-272-23-4
0668
1 23 2 22 21 3 4 5 6 19 7 18 18 17 16 15 14 13 12 11 10
M5251DAA
24
25
20
28
27
26
8 9
Front Winch Installation.
0668-5
TM 9-2320-272-23-4
0668
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Fill hydraulic reservoir to proper fluid level. (Volume 5, WP 0820) Fill front winch to proper fluid level. (Volume 5, WP 0820) Install front winch cable. (WP 0684) Operate front winch and check for leaks. (TM 9-2320-272-10) Install front bumper. (Volume 3, WP 0516)
0668-6
TM 9-2320-272-23-4
0669
FIELD MAINTENANCE REAR WINCH ADJUSTMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Rod, 5/8" Diameter References TM 9-2320-272-10 Equipment Condition Rear winch cable removed. (WP 0710)
CABLE TENSIONER CHECK 1. 2. 3. 4. Start engine (TM 9-2320-272-10) and allow air system to build to normal operating pressure. Place cable tensioner control valve lever (Figure 1, Item 1) in ON position. Place test rod (Figure 1, Item 3) between sheaves (Figure 1, Item 2). If rod (Figure 1, Item 3) cannot be inserted or fits loosely, see CABLE TENSIONER ADJUSTMENT. Stop engine (TM 9-2320-272-10) and remove test rod (Figure 1, Item 3) if adjustment is not required.
2 1 3 2 4
5 6
10
9 8 7
M5252DAA
Cable Tensioner Check.
0669-1
TM 9-2320-272-23-4
0669
CABLE TENSIONER ADJUSTMENT 1. 2. 3. 4. 5. 6. 7. Remove cotter pin (Figure 2, Item 6), pin (Figure 2, Item 8), and pushrod yoke (Figure 2, Item 7) from pivot arm (Figure 2, Item 5). Place test rod (Figure 2, Item 3) between sheaves (Figure 2, Item 2) on cable tensioner (Figure 2, Item 4). Loosen jamnut (Figure 2, Item 9) on pushrod (Figure 2, Item 10). Position pivot arm (Figure 2, Item 5) so sheaves (Figure 2, Item 2) are against test rod (Figure 2, Item 3). Turn pushrod yoke (Figure 2, Item 7) until holes in pushrod (Figure 2, Item 10) and pivot arm (Figure 2, Item 5) align. Install pushrod yoke (Figure 2, Item 7) on pivot arm (Figure 2, Item 5) with pin (Figure 2, Item 8) and pin (Figure 2, Item 6). Tighten jamnut (Figure 2, Item 9). Place tensioner control valve lever (Figure 2, Item 1) in OFF position and remove test rod (Figure 2, Item 3) from sheaves (Figure 2, Item 2).
2 1 3 2 4
5 6
10
9 8 7
M5253DAA
Figure 2. Cable Tensioner Adjustment. 8. Stop engine (TM 9-2320-272-10).
END OF TASK FOLLOW-ON MAINTENANCE Install rear winch cable. (WP 0710) END OF TASK END OF WORK PACKAGE
0669-2
TM 9-2320-272-23-4
0670
FIELD MAINTENANCE REAR WINCH REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Chain Assembly (Volume 5, WP 0826, Table 1, Item 15) Materials/Parts Lockwasher (Volume 5, WP 0827, Table 1, Item 186) Qty: 7 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Boom jack base plates removed. (TM 9-2320-272-10) Rear winch oil drained. (Volume 5, WP 0820) Rear winch cable removed. (WP 0710) Housing assembly cover removed. (WP 0665)
REMOVAL 1. Remove cotter pin (Figure 1, Item 1), pin (Figure 1, Item 4), and pushrod yoke (Figure 1, Item 3) from pivot arm (Figure 1, Item 2).
4 3 2
M5256DAA
Figure 1.
Rear Winch Removal.
0670-1
TM 9-2320-272-23-4
0670
REMOVAL - Continued 2. Remove seven screws (Figure 2, Item 3), lockwashers (Figure 2, Item 4), washers (Figure 2, Item 5), cover (Figure 2, Item 2), and plate (Figure 2, Item 1) from crane body (Figure 2, Item 6). Discard lockwashers.
3 4 5
6
M5258DAA
Figure 2.
Rear Winch Removal.
0670-2
TM 9-2320-272-23-4
0670
REMOVAL - Continued 3. 4. 5. 6. Rotate drive coupling (Figure 3, Item 9) to access cotter pin (Figure 3, Item 4). Remove pin and shear pin (Figure 3, Item 2) from drive coupling. Remove two nuts (Figure 3, Item 10), screws (Figure 3, Item 14), and washers (Figure 3, Item 13) from front motor bracket (Figure 3, Item 12) and crane body (Figure 3, Item 11). Remove two nuts (Figure 3, Item 5), washers (Figure 3, Item 6), screws (Figure 3, Item 8), and washers (Figure 3, Item 6) from rear motor bracket (Figure 3, Item 7) and crane body (Figure 3, Item 11). Slide winch motor (Figure 3, Item 1) forward until clear of winch drive shaft (Figure 3, Item 3).
1 14 13 12 11 4 2 3
10
9 8 6 7 6
M5260DAA
Figure 3.
Rear Winch Removal.
0670-3
TM 9-2320-272-23-4
0670
REMOVAL - Continued 7. Secure chain (Figure 4, Item 2) around rear winch (Figure 4, Item 3) and attach to hoist hook (Figure 4, Item 1). Raise hoist until slack is removed from chain.
1 2 3
M5261DAA
Figure 4.
Rear Winch Removal.
0670-4
TM 9-2320-272-23-4
0670
REMOVAL - Continued
WARNING
NOTE
Mechanic will direct hoisting operation. Assistant will operate hoist. Refer to (TM 9-2320-272-10) for crane operating instructions. 8. 9. 10. Remove four nuts (Figure 5, Item 2), screws (Figure 5, Item 5), and washers (Figure 5, Item 4) from winch frame mounts (Figure 5, Item 3) and crane body (Figure 5, Item 6). Remove rear winch (Figure 5, Item 1) from vehicle. Remove chains from hoist hook and rear winch (Figure 5, Item 1).
3 4 5 6
M5262DAA
Rear Winch Removal.
0670-5
TM 9-2320-272-23-4
0670
INSTALLATION 1. Secure chain (Figure 6, Item 2) around rear winch (Figure 6, Item 3) and attach to hoist hook (Figure 6, Item 1). Raise hoist until slack is removed from chain.
1 2 3
M9818DAA
Figure 6. Rear Winch Installation.
0670-6
TM 9-2320-272-23-4
0670
WARNING
NOTE
Mechanic will direct hoisting operation. Assistant will operate hoist. Refer to (TM 9-2320-272-10) for crane operating instructions. 2. 3. 4. Lift rear winch (Figure 7, Item 1) into position on crane body (Figure 7, Item 6) and align winch drive shaft (Figure 7, Item 7) and winch frame mounts (Figure 7, Item 3). Remove chain (Figure 6, Item 2) from hoist hook (Figure 6, Item 1) and rear winch (Figure 6, Item 3). Install four washers (Figure 7, Item 4), screws (Figure 7, Item 5), and nuts (Figure 7, Item 2) on winch frame mounts (Figure 7, Item 3) and crane body (Figure 7, Item 6).
3 4 5 6 7
M9819DAA
Figure 7.
Rear Winch Installation.
0670-7
TM 9-2320-272-23-4
0670
INSTALLATION - Continued 5. Slide winch motor (Figure 8, Item 16) backward to position at rear winch (Figure 8, Item 1), align holes in drive coupling (Figure 8, Item 10) and winch drive shaft (Figure 8, Item 3) and install shear pin (Figure 8, Item 2) and cotter pin (Figure 8, Item 4). Install front mounting bracket (Figure 8, Item 13) on crane body (Figure 8, Item 12) with two washers (Figure 8, Item 14), screws (Figure 8, Item 15), and nuts (Figure 8, Item 11). Install rear mounting bracket (Figure 8, Item 7) on crane body (Figure 8, Item 12) with two washers (Figure 8, Item 8), screws (Figure 8, Item 9), washers (Figure 8, Item 6), and nuts (Figure 8, Item 5).
6. 7.
16 15 14 13 12 4 2 3
11
10 9 8 7 6
M5263DAA
Figure 8. Rear Winch Installation.
0670-8
TM 9-2320-272-23-4
0670
INSTALLATION - Continued 8. Position plate (Figure 9, Item 1) and cover (Figure 9, Item 2) over winch motor (Figure 8, Item 16) and install on crane body (Figure 9, Item 6) with seven washers (Figure 9, Item 5), lockwashers (Figure 9, Item 4), and screws (Figure 9, Item 3).
3 4 5
6
M5259DAA
Figure 9.
Rear Winch Installation.
0670-9
TM 9-2320-272-23-4
0670
INSTALLATION - Continued 9. Install pushrod yoke (Figure 10, Item 3) on pivot arm (Figure 10, Item 2) with pin (Figure 10, Item 4) and cotter pin (Figure 10, Item 1).
4 3 2
M5257DAA
Figure 10. Rear Winch Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. Fill rear winch to proper fluid level. (Volume 5, WP 0820) Adjust rear winch cable tensioner. (WP 0669) Install rear winch cable. (WP 0710) Operate rear winch and check for leaks. (TM 9-2320-272-10) Install boom jack base plates. (TM 9-2320-272-10) Install housing assembly cover. (WP 0665) Lubricate winch. (Volume 5, WP 0820)
0670-10
TM 9-2320-272-23-4
0671
FIELD MAINTENANCE WINCH FRAME EXTENSION REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Wrench, Torque, Click, Ratcheting, 1/2" Drive, 250 Ft-Lb (Volume 5, WP 0826, Table 1, Item 63) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 288) Qty: 24 Materials/Parts (cont.) Locknut (Volume 5, WP 0827, Table 1, Item 313) Qty: 4 Lockwasher (Volume 5, WP 0827, Table 1, Item 405) Qty: 6 Equipment Condition Front bumper and plates removed. (Volume 3, WP 0515) Front winch removed. (WP 0668) Hood removed. (WP 0565)
0671-1
TM 9-2320-272-23-4
0671
REMOVAL 1. 2. 3. 4. 5. 6. Remove six screws (Figure 1, Item 9), lockwashers (Figure 1, Item 8), washers (Figure 1, Item 7), and two brackets (Figure 1, Item 22) from frame extensions (Figure 1, Item 1). Discard lockwashers. Remove four locknuts (Figure 1, Item 24), screws (Figure 1, Item 5), washers (Figure 1, Item 4), and two loop tiedowns (Figure 1, Item 3) from frame extensions (Figure 1, Item 1). Discard locknuts. Remove eight locknuts (Figure 1, Item 23), screws (Figure 1, Item 6), and two frame extensions (Figure 1, Item 1) from channel reinforcements (Figure 1, Item 2). Discard locknuts. Remove four locknuts (Figure 1, Item 17), screws (Figure 1, Item 21), and washers (Figure 1, Item 10) from two end supports (Figure 1, Item 19) and crossmember (Figure 1, Item 20). Discard locknuts. Remove four locknuts (Figure 1, Item 18), screws (Figure 1, Item 13), and two end supports (Figure 1, Item 19) from channel reinforcements (Figure 1, Item 2). Discard locknuts. Remove eight locknuts (Figure 1, Item 11), screws (Figure 1, Item 12), two screws (Figure 1, Item 16), washers (Figure 1, Item 15), and two channel reinforcements (Figure 1, Item 2) from frame rails (Figure 1, Item 14). Discard locknuts.
0671-2
TM 9-2320-272-23-4
0671
REMOVAL - Continued
1 2
1 24 3 4 5
23 22 2
6 22 21 7 8 9 10 20 19 18 17 11 13 2 14 12 11
15 12 16
M5064DAA
Winch Frame Extension Removal.
0671-3
TM 9-2320-272-23-4
0671
INSTALLATION 1. Install two channel reinforcements (Figure 2, Item 2) on frame rails (Figure 2, Item 4) with eight screws (Figure 2, Item 12), locknuts (Figure 2, Item 11), two washers (Figure 2, Item 15) and screws (Figure 2, Item 16). Tighten locknuts and screws to 85 lb-ft (115 Nm). Install two end supports (Figure 2, Item 19) on channel reinforcements (Figure 2, Item 2) with four screws (Figure 2, Item 13) and locknuts (Figure 2, Item 18). Tighten locknuts to 120 lb-ft (163 Nm). Install two end supports (Figure 2, Item 19) on crossmember (Figure 2, Item 20) with four washers (Figure 2, Item 10), screws (Figure 2, Item 21), and locknuts (Figure 2, Item 17). Tighten locknuts to 120 lb - ft (163 Nm). Install two frame extensions (Figure 2, Item 1) on channel reinforcements (Figure 2, Item 2) with eight screws (Figure 2, Item 6) and locknuts (Figure 2, Item 23). Tighten locknuts to 85 lb-ft (115 Nm). Install two loop tiedowns (Figure 2, Item 3) on frame extensions (Figure 2, Item 1) with four washers (Figure 2, Item 4), screws (Figure 2, Item 5), and locknuts (Figure 2, Item 24). Install two brackets (Figure 2, Item 22) on frame extensions (Figure 2, Item 1) with six washers (Figure 2, Item 7), lockwashers (Figure 2, Item 8), and screws (Figure 2, Item 9).
2. 3.
4. 5. 6.
0671-4
TM 9-2320-272-23-4
0671
1 2
1 24 3 4 5
23 22 2
6 22 21 7 8 9 10 20 19 18 17 11 13 2 14 12 11
15 12 16
M5065DAA
Winch Frame Extension Installation.
0671-5
TM 9-2320-272-23-4
0671
FOLLOW-ON MAINTENANCE 1. 2. 3. Install hood. (WP 0565) Install front winch. (WP 0668) Install bumper and plates. (Volume 3, WP 0515)
0671-6
TM 9-2320-272-23-4
0672
FIELD MAINTENANCE FRONT WINCH AUTOMATIC BRAKE ADJUSTMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10)
0672-1
TM 9-2320-272-23-4
0672
TESTING
CAUTION
Selection of grade used in this procedure should be within the tolerance capabilities of the second vehicle. Failure to comply may result in damage to equipment.
NOTE
The procedures for testing and adjustment of front and rear winch automatic brakes are the same. This procedure covers the front winch automatic brake. Refer to TM 9-2320-272-10 for winch operation. 1. 2. Position test vehicle (Figure 1, Item 1) at top of steep grade, facing downhill, with engine running (TM 9-2320-272-10). Position second vehicle (Figure 1, Item 4) at bottom of steep grade, facing uphill, with engine running. Refer to operator's manual for second vehicle.
WARNING
Never stand between vehicles during test. Assistant must remain in second vehicle to engage service brakes if cable snaps or winch automatic brake fails while towing vehicle. Failure to comply may result in injury or death to personnel. Wear hand protection when handling winch cable. Broken wires may be sharp. Failure to comply may result in injury or death to personnel. A minimum of four turns of cable must remain on winch drum at all times. Failure to comply may result in damage to equipment, injury, or death to personnel. 3. 4. Release winch cable (Figure 1, Item 3) (TM 9-2320-272-10) from test vehicle (Figure 1, Item 1) and rig to second vehicle (Figure 1, Item 4). Refer to Operator's Manual for second vehicle (Figure 1, Item 4) and prepare vehicle (Figure 1, Item 1) as follows: a. b. c. 5. 6. Place transmission lever (Figure 1, Item 5) in NEUTRAL position. Disengage parking brake (TM 9-2320-272-10). Disengage front wheel drive lever if engaged (TM 9-2320-272-10).
Prepare front winch (Figure 1, Item 2) of vehicle (Figure 1, Item 1) for winding (TM 9-2320-272-10). Pull back winch control lever (Figure 1, Item 6) to WIND position, pull second vehicle (Figure 1, Item 4) part way up grade, and observe movement of second vehicle. a. b. If second vehicle (Figure 1, Item 4) rolls backward, go to ADJUSTMENT and adjust automatic winch brake of vehicle (Figure 1, Item 1). If second vehicle (Figure 1, Item 4) holds steady on the incline, no adjustment is required.
7. 8.
Push winch control lever (Figure 1, Item 6) forward to WINCH position and unwind winch cable (Figure 1, Item 3) until second vehicle (Figure 1, Item 4) is on level ground. Remove winch cable (Figure 1, Item 3) from second vehicle (Figure 1, Item 4) if no adjustment is required.
0672-2
TM 9-2320-272-23-4
0672
TESTING - Continued
5 6 2 3
4 25
M5227DAA
Figure 1. Front Winch Automatic Brake Testing. END OF TASK
0672-3
TM 9-2320-272-23-4
0672
ADJUSTMENT 1. 2. Adjust brake band by turning adjustment screw (Figure 2, Item 1) clockwise in one-half turn increments to increase brake action enough to hold second vehicle (Figure 1, Item 4) steady on incline. Repeat TESTING, Steps (4) through (8) until adjustment is correct.
M5228DAA
Front Winch Automatic Brake Adjustment.
Rewind winch cable. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0672-4
TM 9-2320-272-23-4
0673
FIELD MAINTENANCE FRONT WINCH DRAG BRAKE ADJUSTMENT
TESTING
WARNING
Wear hand protection when handling winch cable. Do not handle cable with bare hands. Broken wires may be sharp. Failure to comply may result in injury or death to personnel. 1. Pull out drum lock knob (Figure 1, Item 2) on left side of front winch (Figure 1, Item 1), rotate 90 degrees, and release.
1 2
M5229DAA
Figure 1.
Front Winch Drag Brake Testing.
0673-1
TM 9-2320-272-23-4
0673
TESTING - Continued
NOTE
Perform Steps (2) and (3) for M936/A1 model vehicles equipped with level wind. M936A2 models do not have a level wind. 2. 3. 4. 5. Pull out level wind lock knob (Figure 2, Item 2) on level wind frame (Figure 2, Item 1), rotate one-quarter turn, and release. Pull out cable tensioner lock knob (Figure 2, Item 6) and release tensioner lever (Figure 2, Item 5). Push clutch lever (Figure 2, Item 3) toward front of vehicle to disengage clutch. Pull winch cable (Figure 2, Item 7) 3 to 4 ft (0.9 to 1.2 m) off drum. Drum will stop turning as soon as pulling has stopped if drag brake is properly adjusted. If drum continues to turn after pulling has stopped, perform ADJUSTMENT to adjust drag brake.
1 2 3
4
M9523DAA
Front Winch Drag Brake Testing.
0673-2
TM 9-2320-272-23-4
0673
ADJUSTMENT 1. Turn drag brake adjusting screw (Figure 3, Item 2), located under front winch (Figure 3, Item 1), one-quarter turn clockwise to increase drag; counterclockwise to decrease drag.
M5231DAA
Figure 3. Front Winch Drag Brake Adjustment. 2. Repeat Step (1) until drag brake is properly adjusted.
END OF TASK FOLLOW-ON MAINTENANCE Rewind winch cable. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0673-3/4 blank
TM 9-2320-272-23-4
0674
FIELD MAINTENANCE FRONT WINCH CABLE CHAIN AND HOOK REPLACEMENT
REMOVAL 1. 2. Remove cable chain and hook (Figure 1, Item 1) from front bumper lifting shackle (Figure 1, Item 2). Remove nut (Figure 1, Item 5), clevis pin (Figure 1, Item 3), and clevis (Figure 1, Item 4) from cable chain and hook (Figure 1, Item 1).
3 2 1 4 5
M5232DAA
Figure 1. Front Winch Cable Chain and Hook Removal. END OF TASK
0674-1
TM 9-2320-272-23-4
0674
INSTALLATION 1. 2. Install cable chain and hook (Figure 2, Item 1) on clevis (Figure 2, Item 4) with clevis pin (Figure 2, Item 3) and nut (Figure 2, Item 5). Store cable chain and hook (Figure 2, Item 1) on front bumper lifting shackle (Figure 2, Item 2) for travel.
3 2 1 4 5
M5233DAA
Figure 2. Front Winch Cable Chain and Hook Installation. END OF TASK END OF WORK PACKAGE
0674-2
TM 9-2320-272-23-4
0675
FIELD MAINTENANCE FRONT WINCH CABLE CLEVIS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Vise, Machinist's (Volume 5, WP 0826, Table 1, Item 59) References TB 43-0142 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Front winch cable unwound. (TM 9-2320-272-10) Cable chain and hook removed. (WP 0674)
0675-1
TM 9-2320-272-23-4
0675
REMOVAL
WARNING
Wear hand protection when handling winch cable. Do not handle cable with bare hands. Broken wires may be sharp. Failure to comply may result in injury or death to personnel. 1. 2. 3. Place threaded sleeve (Figure 1, Item 2) in vise (Figure 1, Item 3). Remove clevis socket (Figure 1, Item 1) from threaded sleeve (Figure 1, Item 2). Remove threaded sleeve (Figure 1, Item 2) from vise (Figure 1, Item 3).
3
M5234DAA
Figure 1. Front Winch Cable Clevis Removal.
0675-2
TM 9-2320-272-23-4
0675
REMOVAL - Continued 4. 5. 6. Clamp cable (Figure 2, Item 3) in vise (Figure 2, Item 4) below seizing wire (Figure 2, Item 1), if present. Remove plug (Figure 2, Item 2), threaded sleeve (Figure 2, Item 5), and seizing wire (Figure 2, Item 1), if present, from cable (Figure 2, Item 3). Remove cable (Figure 2, Item 3) from vise (Figure 2, Item 4) and trim to provide new end.
1 2
5 3
4
M5235DAA
Front Winch Cable Clevis Removal.
0675-3
TM 9-2320-272-23-4
0675
INSTALLATION
WARNING
Top seizing must not be less than 5.0 in. (12.7 cm) from end of cable. Faulty installation will cause cable failure. Failure to comply may result in injury or death to personnel. 1. 2. Place cable (Figure 3, Item 1) in vise with 5 1/2 in. (14.0 cm) of cable (Figure 3, Item 1) above jaws of vise. Measure 5.0 in. (12.7 cm) below end of cable (Figure 3, Item 1). Beginning at this point, wrap 1/2 in. (12.7 mm) of mechanic's wire (Figure 3, Item 2) around cable toward vise. Twist ends of mechanic's wire together and bend flat in a groove of cable.
5 IN.
5 1/2 IN. 2
M5236DAA
Figure 3. Front Winch Cable Clevis Installation.
NOTE
If cable is wire-core type, proceed to Step (5). 3. 4. Unravel six strands (Figure 4, Item 2 and 4) of cable (Figure 4, Item 3) above vise. Cut off hemp core (Figure 4, Item 1) as close to vise as possible.
0675-4
TM 9-2320-272-23-4
0675
1 4 3 2
M5237DAA
Figure 4. 5.
Front Winch Cable Clevis Installation.
Wrap upper ends of strands (Figure 5, Item 2) with mechanic's wire (Figure 5, Item 3).
NOTE
Approximately 1-3/8 in. (3.5 cm) of cable should extend above threaded sleeve. 6. 7. 8. Slide threaded sleeve (Figure 5, Item 1) over end of cable (Figure 5, Item 5) and seat against mechanic's wire (Figure 5, Item 4). Remove cable (Figure 5, Item 5) from vise and reclamp on the hex-flats of threaded sleeve (Figure 5, Item 1). Remove upper wire (Figure 5, Item 3) from cable (Figure 5, Item 5).
1 5 4 2 3
M5238DAA
Figure 5.
0675-5
TM 9-2320-272-23-4
0675
NOTE
Use P/N 7071906 plug for hemp core cable. Use P/N 7071871 plug for wire core cable. Perform Step (10) for wire-core type cable. 9. Drive plug (Figure 6, Item 1) into center of cable (Figure 6, Item 4) and into threaded sleeve (Figure 6, Item 3). Align strands (Figure 6, Item 2) with grooves in plug.
1 2 3 4
M5239DAA
Figure 6. Front Winch Cable Clevis Installation. 10. Slide plug (Figure 7, Item 1) over core wire (Figure 7, Item 3) and down onto cable (Figure 7, Item 4), align strands (Figure 7, Item 2) with grooves of plug, and drive plug into cable and threaded sleeve (Figure 7, Item 5).
1 5
2 3 4
M5240DAA
Figure 7. Front Winch Cable Clevis Installation.
0675-6
TM 9-2320-272-23-4
0675
NOTE
Refer to TB 43-0142 for cable and clevis assemblies that must be proof-load tested. 11. Place clevis socket (Figure 8, Item 1) over end of cable (Figure 8, Item 3) and install on threaded sleeve (Figure 8, Item 4). Tighten clevis socket on threaded sleeve until only 3 to 5 threads are exposed. Ensure cable is visible through inspection hole (Figure 8, Item 2) of clevis socket (Figure 8, Item 1).
1
4 3
M5241DAA
Install cable chain and hook. (WP 0674) Wind front winch cable. (TM 9-2320-272-10)
0675-7/8 blank
TM 9-2320-272-23-4
0676
FIELD MAINTENANCE REAR WINCH ROLLER REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cleaning Compound, Solvent (Volume 5, WP 0825, Table 1, Item 16, 17) Grease, Automotive and Artillery (Volume 5, WP 0825, Table 1, Item 28) Lubricating Oil, Engine (Volume 5, WP 0825, Table 1, Item 39, 40, 41, 42) Felt Washer (Volume 5, WP 0827, Table 1, Item 213) Qty: 4 Lockwasher Materials/Parts (cont.) (Volume 5, WP 0827, Table 1, Item 62) Qty: 4 Lockwasher (Volume 5, WP 0827, Table 1, Item 408) Qty: 2 Personnel Required (2) References TM 9-214 Volume 5, WP 0820 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0676-1
TM 9-2320-272-23-4
0676
SIDE ROLLER DISASSEMBLY
NOTE
Repair procedures for both side rollers are the same. This procedure covers the left side roller. 1. Remove two screws (Figure 1, Item 6), lockwashers (Figure 1, Item 7), and lockplate (Figure 1, Item 8) from bracket (Figure 1, Item 3). Discard lockwashers.
NOTE
Assistant will help with Steps (2) and (3). 2. 3. 4. 5. 6. Remove shaft (Figure 1, Item 5) from bracket (Figure 1, Item 3). Remove roller (Figure 1, Item 12), two thrust washers (Figure 1, Item 9), and felt washers (Figure 1, Item 10) from bracket (Figure 1, Item 3). Discard felt washers. Remove two bearings (Figure 1, Item 11) from roller (Figure 1, Item 12). Remove two screws (Figure 1, Item 1), lockwashers (Figure 1, Item 14), plate (Figure 1, Item 2), and spacer (Figure 1, Item 13) from bracket (Figure 1, Item 3). Discard lockwashers. Remove two grease fittings (Figure 1, Item 4) from shaft (Figure 1, Item 5).
1 14 13 9 10 11 12 11 10 9 8 7 6 4
M3033DAA
2 3
Figure 1. Rear Winch Roller Repair - Side Roller Disassembly. END OF TASK
0676-2
TM 9-2320-272-23-4
0676
TOP AND BOTTOM ROLLER DISASSEMBLY
NOTE
Perform left side roller removal if bottom roller is to be repaired. 1. 2. Remove two grease fittings (Figure 2, Item 6) from shaft (Figure 2, Item 7). Remove two screws (Figure 2, Item 9), lockwashers (Figure 2, Item 10), and lockplate (Figure 2, Item 8) from bracket (Figure 2, Item 11). Discard lockwashers.
NOTE
Thrust washers may fall out. 3. 4. Remove shaft (Figure 2, Item 7) from roller (Figure 2, Item 5). Remove two grease fittings (Figure 2, Item 1) from tensioner sheave shaft (Figure 2, Item 12).
NOTE
Assistant will help with Step (5). 5. 6. Remove roller (Figure 2, Item 5) and two thrust washers (Figure 2, Item 2) from bracket (Figure 2, Item 11). Remove two felt washers (Figure 2, Item 3) and bearings (Figure 2, Item 4) from roller (Figure 2, Item 5). Discard felt washers.
1 12 2 3 4 11 5 4 3 2 6 7 8
6 10 9
M3034DAA
Figure 2. Rear Winch Roller Repair - Top and Bottom Roller Disassembly. END OF TASK
0676-3
TM 9-2320-272-23-4
0676
WARNING
Solvent cleaning compound is flammable and toxic. Do not use near an open flame and always have a fire extinguisher nearby when solvents are used. Use only in well-ventilated places, wear protective clothing, and dispose of cleaning rags in approved container. Failure to comply may result in damage to equipment, injury, or death to personnel. 1. 2. 3. 4. 5. 6. Clean roller (Figure 3, Item 3) and shafts (Figure 3, Items 4 and 5) assemblies with solvent cleaning compound and allow to air-dry. Inspect shafts (Figure 3, Items 4 and 5) for cracks. Replace shafts, if cracked. Measure bearing surfaces of shafts (Figure 3, Items 4 and 5). If outer diameter of bearing surfaces of shafts is less than 2.245 in. (57.02 mm), replace. Inspect four thrust washers (Figure 3, Items 1 and 6) for cracks. Replace thrust washers if cracked. Measure thickness of thrust washers (Figure 3, Items 1 and 6). If thickness of thrust washers is less than 0.055 in. (1.40 mm), replace. Inspect four bearings (Figure 3, Items 2 and 7) for damage (TM 9-214). If bearings are damaged, replace.
0676-4
TM 9-2320-272-23-4
0676
2 3 2
6 7
7 6 5
M3035DAA
Rear Winch Roller Cleaning and Inspection.
0676-5
TM 9-2320-272-23-4
0676
TOP AND BOTTOM ROLLER ASSEMBLY 1. 2. Pack two bearings (Figure 4, Item 4) with grease and install in roller (Figure 4, Item 5). Soak two felt washers (Figure 4, Item 3) in lubricating oil prior to installation. Position two felt washers and thrust washers (Figure 4, Item 2) on each end of roller (Figure 4, Item 5).
NOTE
Assistant will help with Steps (3) and (4). 3. 4. 5. 6. Slide roller (Figure 4, Item 5), bearing (Figure 4, Item 4), felt washers (Figure 4, Item 3), and thrust washer (Figure 4, Item 2) between brackets (Figure 4, Item 11). Install shaft (Figure 4, Item 7) through brackets (Figure 4, Item 11) and roller (Figure 4, Item 5). Align lockplate (Figure 4, Item 8) with shaft (Figure 4, Item 7) and install with two lockwashers (Figure 4, Item 10) and screws (Figure 4, Item 9). Install two grease fittings (Figure 4, Item 6) on shaft (Figure 4, Item 7).
NOTE
Install left side roller if removed (Refer to SIDE ROLLER ASSEMBLY). 7. Install two grease fittings (Figure 4, Item 1) on tensioner sheave shaft (Figure 4, Item 12).
1 12 2 3 4 11 5 4 3 2 6 7 8
6 10 9
M9937DAA
Figure 4. Rear Winch Roller Repair - Top and Bottom Roller Assembly. END OF TASK
0676-6
TM 9-2320-272-23-4
0676
SIDE ROLLER ASSEMBLY 1. 2. 3. 4. Install two grease fittings (Figure 5, Item 4) on shaft (Figure 5, Item 5). Install spacer (Figure 5, Item 13) on bracket (Figure 5, Item 3) with plate (Figure 5, Item 2), two lockwashers (Figure 5, Item 14), and screws (Figure 5, Item 1). Pack two bearings (Figure 5, Item 11) with grease and install in roller (Figure 5, Item 12). Soak two felt washers (Figure 5, Item 10) in lubricating oil prior to installation. Position two felt washers and thrust washers (Figure 5, Item 9) on each end of roller (Figure 5, Item 12).
NOTE
Assistant will help with Steps (5) and (6). 5. 6. 7. Slide roller (Figure 5, Item 12), bearing (Figure 5, Item 11), felt washers (Figure 5, Item 10), and thrust washers (Figure 5, Item 9) into bracket (Figure 5, Item 3). Install shaft (Figure 5, Item 5) through bracket (Figure 5, Item 3) and roller (Figure 5, Item 12). Make sure locking slot is at bottom. Align lockplate (Figure 5, Item 8) with shaft (Figure 5, Item 5) and install with two lockwashers (Figure 5, Item 7) and screws (Figure 5, Item 6).
1 14 13 9 10 11 12 11 10 9 8 7 6 4
M9938DAA
2 3
Figure 5. Rear Winch Roller Repair - Side Roller Assembly. END OF TASK
0676-7
TM 9-2320-272-23-4
0676
FOLLOW-ON MAINTENANCE Lubricate roller assembly. (Volume 5, WP 0820) END OF TASK END OF WORK PACKAGE
0676-8
TM 9-2320-272-23-4
0677
FIELD MAINTENANCE FRONT WINCH CABLE TENSIONER REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Hammer, Soft Face (Volume 5, WP 0826, Table 1, Item 22) Press, Arbor, Hand Operated (Volume 5, WP 0826, Table 1, Item 39) Materials/Parts Cloth, Cleaning (Volume 5, WP 0825, Table 1, Item 19) Grease, Automotive and Artillery (Volume 5, WP 0825, Table 1, Item 28) Lockwasher (Volume 5, WP 0827, Table 1, Item 186) Qty: 4 Lockwasher (Volume 5, WP 0827, Table 1, Item 405) Qty: 4 Materials/Parts (cont.) Packing Assembly (Volume 5, WP 0827, Table 1, Item 221) Qty: 4 Woodruff Key (Volume 5, WP 0827, Table 1, Item 414) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10) Winch cable removed. (WP 0674)
0677-1
TM 9-2320-272-23-4
0677
REMOVAL 1. 2. 3. 4. 5. Remove four nuts (Figure 1, Item 2), lockwashers (Figure 1, Item 3), screws (Figure 1, Item 4), and cable tensioner (Figure 1, Item 8) from brackets of roller assembly (Figure 1, Item 1). Discard lockwashers. Remove two grease fittings (Figure 1, Item 9) from cable tensioner (Figure 1, Item 8). Remove setscrew (Figure 1, Item 6), lever (Figure 1, Item 5), and poppet assembly (Figure 1, Item 7) from tensioner (Figure 1, Item 8). Remove latch nut (Figure 1, Item 14), latch (Figure 1, Item 10), and winch poppet nut (Figure 1, Item 13) from poppet (Figure 1, Item 12). Remove spring (Figure 1, Item 11) and poppet (Figure 1, Item 12) from poppet nut (Figure 1, Item 13).
2 1 11 10 8 12 13 14 7 5 6
Figure 1. Cable Tensioner Removal. 6. 7. 8. 9. 10. 11. 12. 13. 14.
3 4
M6000DAA
Remove four screws (Figure 2, Item 12), lockwashers (Figure 2, Item 13), and block assembly (Figure 2, Item 10) from frame (Figure 2, Item 14). Discard lockwashers. Remove shaft (Figure 2, Item 8) from frame (Figure 2, Item 14). Remove bushing (Figure 2, Item 11), woodruff key (Figure 2, Item 9), and bushing (Figure 2, Item 7) from shaft (Figure 2, Item 8). Discard woodruff key and tag parts for installation. Remove sheave (Figure 2, Item 4), two packing assemblies (Figure 2, Items 2 and 5), and thrust washers (Figure 2, Items 1 and 6) from frame (Figure 2, Item 14). Discard packing assemblies. Remove bearing (Figure 2, Item 3) from sheave (Figure 2, Item 4). Remove two snaprings (Figure 2, Item 19) from tensioner sheave pin (Figure 1, Item 20). Remove tensioner sheave pin (Figure 1, Item 20) and pin (Figure 1, Item 21) from frame (Figure 2, Item 14). Remove sheave (Figure 2, Item 18), two packing assemblies (Figure 2, Item 16), and thrust washers (Figure 2, Item 15) from frame (Figure 2, Item 14). Discard packing assemblies. Remove bearing (Figure 2, Item 17) from sheave (Figure 2, Item 18).
0677-2
TM 9-2320-272-23-4
0677
REMOVAL - Continued
1 2 3 4 5 6
12
13
14
11
10
8 18 15 16 17 16
15
19 14 21 20 19
M6001DAA
Cable Tensioner Disassembly.
0677-3
TM 9-2320-272-23-4
0677
CLEANING AND INSPECTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Inspect frame (Figure 3, Item 1) for breaks and cracks. Replace if broken or cracked. Clean tensioner sheave pin (Figure 3, Item 14) and inspect for pits, scoring, and wear. Replace if scored, pitted, or if outside diameter is less than 0.9995 in. (25.39 mm). Clean sheave (Figure 3, Item 12) and inspect for breaks and cracks. Replace if broken or cracked. Clean bearing (Figure 3, Item 11) and inspect for cracks, chips, and broken cage. Replace if cracked, chipped, broken, or if inner diameter exceeds 1.000 in. (25.4 mm). Clean two thrust washers (Figure 3, Item 9) and inspect for cracks, chips, and wear. Replace if cracked, chipped, or if thickness is less than 0.0615 in. (1.56 mm). Clean block (Figure 3, Item 4) and inspect for cracks and elongated holes. Replace if cracked or holes are elongated. Clean shaft (Figure 3, Item 3) and inspect for cracks. Replace if cracked. Measure outer cam diameter of shaft (Figure 3, Item 3). Replace if cam outer diameter is less than 0.995 in. (25.35 mm). Measure outer diameter of bearing (Figure 3, Item 11). Replace if outer diameter is less than 0.748 in. (18.99 mm). Clean sheave (Figure 3, Item 12) and inspect for cracks and wear. Replace if cracked or broken. Clean two thrust washers (Figure 3, Item 9) and inspect for cracks and wear. Replace if cracked or if thickness is less than 0.062 in. (1.56 mm). Clean bearing (Figure 3, Item 11) and inspect for cracks, chips, and broken cage. Replace if cracked, chipped, or broken. Measure inner diameter of bearing (Figure 3, Item 11) and replace if inner diameter is greater than 1.000 in. (25.4 mm). Clean two bushings (Figure 3, Item 2) and inspect for cracks, chips, and wear. Replace if cracked, chipped, or if inner diameter exceeds 0.754 in. (19.15 mm). Clean frame (Figure 3, Item 1) and replace if damaged. Clean latch (Figure 3, Item 8) and lever (Figure 3, Item 7) and inspect for breaks and cracks. Replace if broken or cracked. Clean poppet (Figure 3, Item 5) and inspect for bends and breaks. Replace if bent or broken. Clean spring (Figure 3, Item 6) and inspect for broken and collapsed coils. Replace if coils are broken or collapsed.
0677-4
TM 9-2320-272-23-4
0677
2 1 7 4 6 8
5 3
12
10
11 9 10 13
1 15 16 17
14
Figure 3. END OF TASK Cable Tensioner Cleaning and Inspection.
M6002DAA
0677-5
TM 9-2320-272-23-4
0677
INSTALLATION
NOTE
Ensure all bearings are packed with GAA grease before installation. 1. 2. 3. 4. 5. 6. Using arbor press, install bearing (Figure 4, Item 10) in sheave (Figure 4, Item 1). Using soft-faced hammer, drive pin (Figure 4, Item 8) into tensioner sheave pin (Figure 4, Item 6) until seated. Install snapring (Figure 4, Item 7) on pin (Figure 4, Item 6). Position felt side of two packing assemblies (Figure 4, Item 2) against bearing (Figure 4, Item 10). Position sheave (Figure 4, Item 1) and two thrust washers (Figure 4, Item 3) in frame (Figure 4, Item 5) and install with tensioner sheave pin (Figure 4, Item 6). Secure tensioner sheave pin (Figure 4, Item 6) on frame (Figure 4, Item 5) with snapring (Figure 4, Item 4). Ensure tensioner sheave pin engages slot (Figure 4, Item 9) in frame.
10 3 2 4
5 7 8 9
6
Figure 4. Cable Tensioner Assembly.
M6003DAA
0677-6
TM 9-2320-272-23-4
0677
INSTALLATION - Continued 7. 8. 9. 10. 11. 12. Using arbor press, install two bushings (Figure 5, Items 4 and 8) in tensioner (Figure 5, Item 11). Using arbor press, install bearing (Figure 5, Item 12) in sheave (Figure 5, Item 1). Position two packing assemblies (Figure 5, Item 2), with felt sides against ends of bearing (Figure 5, Item 12), in sheave (Figure 5, Item 1). Install woodruff key (Figure 5, Item 6) in shaft (Figure 5, Item 5). Position sheave (Figure 5, Item 1) and two thrust washers (Figure 5, Item 3) in tensioner (Figure 5, Item 11) and install shaft (Figure 5, Item 5). Install block (Figure 5, Item 7) on shaft (Figure 5, Item 5) with four lockwashers (Figure 5, Item 10) and screws (Figure 5, Item 9).
3 1 12 2 3 2
11 4 9 10
5 6
M6004DAA
Figure 5.
Cable Tensioner Assembly.
0677-7
TM 9-2320-272-23-4
0677
INSTALLATION - Continued 13. 14. 15. 16. 17. 18. Install lever (Figure 6, Item 6) on shaft (Figure 6, Item 5) with setscrew (Figure 6, Item 7). Install spring (Figure 6, Item 12) and poppet (Figure 6, Item 13) in poppet nut (Figure 6, Item 14). Install latch (Figure 6, Item 11) on poppet (Figure 6, Item 13) with latch nut (Figure 6, Item 15). Install poppet assembly (Figure 6, Item 8) in lever (Figure 6, Item 5) and install with poppet nut (Figure 6, Item 14). Install two grease fittings (Figure 6, Item 10) on cable tensioner (Figure 6, Item 9). Install cable tensioner (Figure 6, Item 9) on roller assembly (Figure 6, Item 1) with four screws (Figure 6, Item 4), lockwashers (Figure 6, Item 3), and nuts (Figure 6, Item 2).
2 1 12 11 10 9 13 14 15 8 6 5
3 4
7
Figure 6. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install winch cable. (WP 0674)
M6005DAA
Cable Tensioner.
Lubricate tensioner assembly. (Volume 5, WP 0820)
0677-8
TM 9-2320-272-23-4
0678
FIELD MAINTENANCE FRONT AND REAR WINCH LEVEL WIND REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Press, Arbor, Hand Operated (Volume 5, WP 0826, Table 1, Item 39) Materials/Parts Grease, Automotive and Artillery (Volume 5, WP 0825, Table 1, Item 28) Lubricating Oil, Gear, Multipurpose (Volume 5, WP 0825, Table 1, Item 44, 45, 46, 47) Bushing (Volume 5, WP 0827, Table 1, Item 216) Qty: 1 Cotter Pin (Volume 5, WP 0827, Table 1, Item 347) Qty: 1 Felt Seal (Volume 5, WP 0827, Table 1, Item 218) Qty: 1 Felt Washer (Volume 5, WP 0827, Table 1, Item 66) Qty: 2 Felt Washer (Volume 5, WP 0827, Table 1, Item 209) Qty: 2 Materials/Parts (cont.) Felt Washer (Volume 5, WP Qty: 1 Locknut (Volume 5, WP Qty: 2 Lockwasher (Volume 5, WP Qty: 8 Lockwasher (Volume 5, WP Qty: 5
0827, Table 1, Item 217)
0827, Table 1, Item 326)
0827, Table 1, Item 186)
0827, Table 1, Item 408)
References Volume 5, WP 0819 Equipment Condition Parking brake set. (TM 9-2320-272-10) Winch cable removed. (WP 0668)
0678-1
TM 9-2320-272-23-4
0678
REMOVAL
NOTE
Front and rear wench level wind are maintained the same way. This procedure covers front level wind. 1. 2. Remove four screws (Figure 1, Item 6) and lockwashers (Figure 1, Item 7) from winch track (Figure 1, Item 1). Discard lockwashers. Remove winch track (Figure 1, Item 1) and level wind (Figure 1, Item 2) from winch (Figure 1, Item 8).
NOTE
Rectangular holes are provided for removing screws. Slide the level wind backward and forward until screws are visible. 3. 4. 5. Remove four screws (Figure 1, Item 13), lockwashers (Figure 1, Item 14), and level wind (Figure 1, Item 2) from winch track (Figure 1, Item 1). Discard lockwashers. Remove two nuts (Figure 1, Item 12), drum lock latch (Figure 1, Item 11), nut (Figure 1, Item 10), spring (Figure 1, Item 9), and poppet (Figure 1, Item 5) from track (Figure 1, Item 1). Remove two outer nuts (Figure 1, Item 4), screws (Figure 1, Item 3), and inner nuts (Figure 1, Item 4) from track (Figure 1, Item 1).
NOTE
Both sets of trolley wheels are removed the same. 6. 7. 8. 9. 10. Remove grease fitting (Figure 1, Item 24) from axle (Figure 1, Item 16). Remove screw (Figure 1, Item 23) and lockwasher (Figure 1, Item 22) from axle (Figure 1, Item 16). Discard lockwasher. Remove three washers (Figure 1, Item 18), two felt washers (Figure 1, Item 19), wheel (Figure 1, Item 21), and thrust washer (Figure 1, Item 17) from axle (Figure 1, Item 16). Discard felt washers. Using arbor press, remove axle (Figure 1, Item 16) from level wind (Figure 1, Item 15). Using arbor press, remove bearing (Figure 1, Item 20) from wheel (Figure 1, Item 21).
0678-2
TM 9-2320-272-23-4
0678
REMOVAL - Continued
1 13 14
3 4
5 6 7
9 11 12 10
15 16 18 17 19 18 22 24 23 21 20
19
M6006DAA
Figure 1.
Level Wind Disassembly.
0678-3
TM 9-2320-272-23-4
0678
REMOVAL - Continued 11. 12. 13. 14. Remove four screws (Figure 2, Item 3), lockwashers (Figure 2, Item 2), and sheave guard (Figure 2, Item 1) from frame (Figure 2, Item 11). Discard lockwashers. Remove grease fitting (Figure 2, Item 13), cotter pin (Figure 2, Item 8), slotted nut (Figure 2, Item 9), and washer (Figure 2, Item 10) from screw (Figure 2, Item 12). Discard cotter pin. Remove screw (Figure 2, Item 12) and sheave (Figure 2, Item 14) from frame (Figure 2, Item 11). Thrust washers (Figure 2, Item 7) will fall out. Remove two felt washers (Figure 2, Item 6), sleeve (Figure 2, Item 5), and bearing (Figure 2, Item 4) from sheave (Figure 2, Item 14). Discard felt washers.
0678-4
TM 9-2320-272-23-4
0678
REMOVAL - Continued
7 6
2 3
4 14 5 6 7
13 12 8
9 10 11
M6007DAA
Figure 2.
0678-5
TM 9-2320-272-23-4
0678
REMOVAL - Continued 15. Remove grease fitting (Figure 3, Item 1), locknut (Figure 3, Item 2), washer (Figure 3, Item 3), and felt washer (Figure 3, Item 4) from end of swivel (Figure 3, Item 5) in frame (Figure 3, Item 6). Discard locknut and felt washer. Using arbor press, remove swivel (Figure 3, Item 5) from frame (Figure 3, Item 6). Remove bushing (Figure 3, Item 9), felt seal (Figure 3, Item 12), inner race (Figure 3, Item 13), 45 ball bearings (Figure 3, Item 8), outer race (Figure 3, Item 15), and bearing (Figure 3, Item 7) from frame (Figure 3, Item 6). Discard felt seal and bushing.
16. 17.
NOTE
An arbor press may be required to perform Step (16). 18. Remove locknut (Figure 3, Item 11) and extension (Figure 3, Item 10) from swivel (Figure 3, Item 5). Discard locknut.
0678-6
TM 9-2320-272-23-4
0678
REMOVAL - Continued
6 1
2 15 3 4 8 8 13
12
10
11
M10066DAA
0678-7
TM 9-2320-272-23-4
0678
CLEANING, INSPECTION, AND REPAIR 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Clean track (Figure 4, Item 1) and inspect for cracks and chipped or nicked wheel surface. Discard if cracked. Use file to smooth wheel surface if chipped or nicked. Clean poppet (Figure 4, Item 8) and inspect for cracks, bends, and damaged threads. Discard if cracked, bent, or threads are damaged. Clean spring (Figure 4, Item 7) and inspect for broken or collapsed coils. Discard if coils are broken or collapsed. Clean nut (Figure 4, Item 9) and inspect for damaged threads. Discard if threads are damaged. Clean latch (Figure 4, Item 6) and inspect for cracks. Discard if cracked. Clean nuts (Figure 4, Item 5) and inspect for damaged threads. Discard if threads are damaged. Clean stopscrews (Figure 4, Item 2) and nuts (Figure 4, Items 3 and 4) and inspect for bends, cracks, or damaged threads. Discard if bent, cracked, or threads are damaged. Clean wheel (Figure 4, Item 10) and inspect for cracks and damaged roller surface. Discard if cracked or roller surface is damaged. Inspect bearing (Figure 4, Item 11) for chips, cracks, and damaged cage. Discard if chipped, cracked, or cage is damaged. Clean thrust washer (Figure 4, Item 12) and inspect for cracks and wear. Measure thickness. Discard if cracked or thickness is less than 0.058 in. (1.47 mm). Clean axle (Figure 4, Item 13) and inspect for cracks and scoring. Discard if cracked or scored. Clean screw (Figure 4, Item 18) and inspect for cracks, scoring, and damaged threads. Discard if cracked, scored, or threads are damaged. Clean two thrust washers (Figure 4, Item 14) and inspect for cracks and wear. Measure thickness. Discard if cracked or thickness is less than 0.058 in. (1.47 mm). Clean sheave (Figure 4, Item 17) and inspect for cracks. Discard if cracked. Clean sleeve (Figure 4, Item 16) and inspect for cracks and scoring. Discard if cracked or scored. Inspect bearing (Figure 4, Item 15) for chips, cracks, and damaged cage. Discard if chipped, cracked, or cage is damaged.
0678-8
TM 9-2320-272-23-4
0678
2 3
5 4
13 12 10 11
14
15 16 14
17 18
Figure 4. Level Wind Cleaning and Inspection.
M6008DAA
0678-9
TM 9-2320-272-23-4
0678
CLEANING, INSPECTION, AND REPAIR - Continued 17. 18. 19. 20. Inspect bearing (Figure 5, Item 5) for chips, cracks, and damaged cage. Discard if chipped, cracked, or cage is damaged. Clean inner race (Figure 5, Item 1) and outer race (Figure 5, Item 3) and inspect for pits, chips, and cracks. Discard if pitted, chipped, or cracked. Inspect 45 bearing balls (Figure 5, Item 2) for cracks, chips, and out-of-round condition. Discard any bearing balls that are cracked, chipped, or out-of-round. Clean frame (Figure 5, Item 4) and inspect for cracks and damaged threads. Discard if cracked or threads are damaged.
1
5
M6009DAA
Figure 5. Level Wind Cleaning and Inspection. END OF TASK
0678-10
TM 9-2320-272-23-4
0678
ASSEMBLY
NOTE
Ensure all felt seals are soaked in lubricating oil before installation. Ensure all bearings are packed with GAA grease before installation. 1. 2. 3. 4. 5. 6. 7. Using arbor press, install extension (Figure 6, Item 8) in swivel (Figure 6, Item 10) with locknut (Figure 6, Item 9). Using arbor press, install outer race (Figure 6, Item 3) into frame (Figure 6, Item 5). Position 45 ball bearings (Figure 6, Item 6) on outer race (Figure 6, Item 3). Using arbor press, install inner race (Figure 6, Item 2) in frame (Figure 6, Item 5). Install felt seal (Figure 6, Item 7) over inner race (Figure 6, Item 2). Using arbor press, install bushing (Figure 6, Item 1) in frame (Figure 6, Item 5). Install bearing (Figure 6, Item 4) in bottom of frame (Figure 6, Item 5).
10
7
Figure 6. Level Wind Assembly.
M6010DAA
0678-11
TM 9-2320-272-23-4
0678
ASSEMBLY - Continued 8. 9. 10. 11. 12. 13. Using arbor press, install swivel (Figure 7, Item 1) with extension (Figure 7, Item 2) in frame (Figure 7, Item 7). With swivel (Figure 7, Item 1) and extension (Figure 7, Item 2) seated in frame (Figure 7, Item 7), install felt washer (Figure 7, Item 3), washer (Figure 7, Item 6), and locknut (Figure 7, Item 4) on end of extension. Install grease fitting (Figure 7, Item 5) on end of extension (Figure 7, Item 2). Install bearing (Figure 7, Item 14), sleeve (Figure 7, Item 15), and two felt washers (Figure 7, Item 9) in sheave (Figure 7, Item 13). Coat one side of each of two thrust washers (Figure 7, Item 8) with grease and install on sheave (Figure 7, Item 13) with grease side next to bearing (Figure 7, Item 14). Carefully place sheave (Figure 7, Item 13) and thrust washers (Figure 7, Item 8) in swivel (Figure 7, Item 1) and install with screw (Figure 7, Item 19), washer (Figure 7, Item 18), and slotted nut (Figure 7, Item 17). Ensure that slots in nut align with hole in screw. Install cotter pin (Figure 7, Item 16) in slots of nut (Figure 7, Item 17) and hole in screw (Figure 7, Item 19). Install grease fitting (Figure 7, Item 20) in head end of screw (Figure 7, Item 19). Position sheave guard (Figure 7, Item 10) over sheave (Figure 7, Item 13) and install on swivel (Figure 7, Item 1) with four lockwashers (Figure 7, Item 11) and screws (Figure 7, Item 12).
14. 15. 16.
0678-12
TM 9-2320-272-23-4
0678
1 10 8 9 11 12
13
14 15 9 8
20 19 16 1 3
6 4
18 17
5
M6011DAA
Figure 7.
Level Wind Assembly.
0678-13
TM 9-2320-272-23-4
0678
NOTE
Both sets of trolley wheels are installed the same. An arbor press may be required to perform Step (17). 17. 18. 19. 20. Install axle (Figure 8, Item 9) in frame (Figure 8, Item 10). Install thrust washer (Figure 8, Item 8) on axle (Figure 8, Item 9). Install bearing (Figure 8, Item 7) in wheel (Figure 8, Item 6). Install two washers (Figure 8, Item 4), felt washer (Figure 8, Item 5), wheel (Figure 8, Item 6), felt washer (Figure 8, Item 5), two washers (Figure 8, Item 4), lockwasher (Figure 8, Item 3), and screw (Figure 8, Item 2) on axle (Figure 8, Item 9). Install grease fitting (Figure 8, Item 1) on screw (Figure 8, Item 2). Place spring (Figure 8, Item 18) over poppet (Figure 8, Item 14) and install with nut (Figure 8, Item 19). Install poppet (Figure 8, Item 14) and latch (Figure 8, Item 20) in track (Figure 8, Item 11) with two nuts (Figure 8, Item 21). Place level wind assembly (Figure 8, Item 10) on track (Figure 8, Item 11) and install with four lockwashers (Figure 8, Item 23) and screws (Figure 8, Item 22). Install two stopscrews (Figure 8, Item 12) on track (Figure 8, Item 11) with each screw positioned with two nuts (Figure 8, Item 13). Level wind (Figure 8, Item 10) receives final adjustment when winch (Figure 8, Item 17) is mounted on vehicle.
21. 22. 23. 24. 25.
END OF TASK INSTALLATION Install level wind assembly (Figure 8, Item 10) and track (Figure 8, Item 11) on winch (Figure 8, Item 17) with four lockwashers (Figure 8, Item 16) and screws (Figure 8, Item 15).
0678-14
TM 9-2320-272-23-4
0678
2 3 4 5 6 7 5 4 8 21 18 20 19 22 23 11 12 13
10
14 15
16 13
10
17
9
M6012DAA
Figure 8. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Lubricate level wind. (Volume 5, WP 0819) Install winch cable. (WP 0668)
Level Wind Assembly.
0678-15/16 blank
TM 9-2320-272-23-4
0679
FIELD MAINTENANCE FRONT WINCH ROLLER ASSEMBLY REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Press, Arbor, Hand Operated (Volume 5, WP 0826, Table 1, Item 39) Punch Set, Cutting (Volume 5, WP 0826, Table 1, Item 44) Materials/Parts Cleaning Compound, Solvent (Volume 5, WP 0825, Table 1, Item 16, 17) Grease, Automotive and Artillery (Volume 5, WP 0825, Table 1, Item 28) Lubricating Oil, Gear, Multipurpose (Volume 5, WP 0825, Table 1, Item 44, 45, 46, 47) Lockwasher (Volume 5, WP 0827, Table 1, Item 398) Qty: 2 Lockwasher (Volume 5, WP 0827, Table 1, Item 405) Qty: 2 Materials/Parts (cont.) Lockwasher (Volume 5, WP 0827, Table 1, Item 408) Qty: 8 Lockwasher (Volume 5, WP 0827, Table 1, Item 437) Qty: 4 Packing Assembly (Volume 5, WP 0827, Table 1, Item 222) Qty: 2 References Volume 5, WP 0819 Equipment Condition Parking brake set. (TM 9-2320-272-10) Front winch removed. (WP 0668)
0679-1
TM 9-2320-272-23-4
0679
REMOVAL 1. 2. 3. Remove eight screws (Figure 1, Item 4) and lockwashers (Figure 1, Item 2) from winch roller assembly (Figure 1, Item 5). Discard lockwashers. Remove four screws (Figure 1, Item 3), lockwashers (Figure 1, Item 2), and roller assembly (Figure 1, Item 5) from winch (Figure 1, Item 1). Discard lockwashers. Remove two grease fittings (Figure 1, Item 6), right roller bracket (Figure 1, Item 7), and thrust washer (Figure 1, Item 8) from roller shaft (Figure 1, Item 9).
7 5 8 6 9 6
2 4
2
M6013DAA
Figure 1. Front Winch Roller Assembly Removal. END OF TASK DISASSEMBLY 1. 2. Remove two felt washers (Figure 2, Item 5), bearings (Figure 2, Item 6), and roller (Figure 2, Item 7) from shaft (Figure 2, Item 2). Discard felt washers. Remove thrust washer (Figure 2, Item 1) from shaft (Figure 2, Item 2).
NOTE
Both setscrews are in the same hole. 3. 4. Remove two setscrews (Figure 2, Item 4) from left roller bracket (Figure 2, Item 3). Remove shaft (Figure 2, Item 2) from bracket (Figure 2, Item 3).
0679-2
TM 9-2320-272-23-4
0679
NOTE
Both side rollers are disassembled the same. 5. 6. 7. 8. 9. Remove grease fitting (Figure 2, Item 14) from side roller shaft (Figure 2, Item 15). Remove pin (Figure 2, Item 18) from roller bracket (Figure 2, Item 3) and shaft (Figure 2, Item 15). Remove two thrust washers (Figure 2, Item 16) and roller (Figure 2, Item 17) from bracket (Figure 2, Item 3). Remove two screws (Figure 2, Item 8), lockwashers (Figure 2, Item 9), and small side bracket (Figure 2, Item 19) from large bracket (Figure 2, Item 12). Discard lockwashers. Remove two screws (Figure 2, Item 13), nuts (Figure 2, Item 10), lockwashers (Figure 2, Item 11), and large bracket (Figure 2, Item 12) from roller bracket (Figure 2, Item 3). Discard lockwashers.
3 4
2 6 5 1
7 5 6
13 10 11 12 3 14 15 8 9 16
19 17
18
16
M6014DAA
Roller Assembly Disassembly.
0679-3
TM 9-2320-272-23-4
0679
CLEANING, INSPECTION, AND REPAIR
WARNING
Solvent cleaning compound is flammable and toxic. Do not use near an open flame and always have a fire extinguisher nearby when solvents are used. Use only in well-ventilated places, wear protective clothing, and dispose of cleaning rags in approved container. Failure to comply may result in damage to equipment, injury, or death to personnel. 1. 2. 3. Clean all items with solvent cleaning compound before inspection (Volume 5, WP 0819). Inspect side roller shaft (Figure 3, Item 4) for cracks and wear. Measure outer diameter of shaft at bushing (Figure 3, Item 6) contact points. Discard if cracked or if any outer diameter is less than 0.994 in. (25.25 mm). Inspect bushings (Figure 3, Item 6) for scoring and wear. Measure inner diameter of bushings. Discard if scored or inner diameter is more than 1.010 in. (25.65 mm).
NOTE
Perform Steps (4) and (5) only if bushings are to be replaced. 4. 5. 6. 7. Using arbor press and mandrel, remove two bushings (Figure 3, Item 6) from roller (Figure 3, Item 7). Discard bushings. Install two bushings (Figure 3, Item 6) on roller (Figure 3, Item 7). Inspect thrust washers (Figure 3, Item 5) for cracks and wear. Measure thickness of thrust washers. Discard if cracked or if thickness is less than 0.040 in. (1.02 mm). Inspect roller shaft (Figure 3, Item 1) for cracks, scoring, and wear. Measure diameter where bearings (Figure 3, Item 2) contact shaft. Discard if cracked, scored, or any measured diameter is less than 1.495 in. (37.97 mm). Inspect thrust washers (Figure 3, Item 3) for chips, cracks, scoring, and wear. Measure thickness of thrust washers. Discard if chipped, cracked, scored, or thickness is less than 0.052 in. (1.32 mm). Inspect two bearings (Figure 3, Item 2) for chips, pitting, cracks, and damaged cage. Discard if chipped, pitted, cracked, or cage is damaged.
8. 9.
0679-4
TM 9-2320-272-23-4
0679
1 2 3 6
6 5
M6015DAA
Roller Assembly Cleaning and Inspection.
0679-5
TM 9-2320-272-23-4
0679
ASSEMBLY 1. 2. 3. 4. 5. 6. 7. Install large side bracket (Figure 4, Item 1) on roller bracket (Figure 4, Item 8) with two screws (Figure 4, Item 2), lockwashers (Figure 4, Item 13), and nuts (Figure 4, Item 12). Install small side bracket (Figure 4, Item 9) on large bracket (Figure 4, Item 8) with two lockwashers (Figure 4, Item 10) and screws (Figure 4, Item 11). Lightly coat two thrust washers (Figure 4, Item 5) with grease and position on ends of roller (Figure 4, Item 6). Install roller (Figure 4, Item 6) and thrust washers (Figure 4, Item 5) on roller bracket (Figure 4, Item 8). Align holes in washers and roller with holes in bracket. Align pin (Figure 4, Item 7) holes in shaft (Figure 4, Item 4) and bracket (Figure 4, Item 8), and install shaft on bracket and through roller (Figure 4, Item 6). Install pin (Figure 4, Item 7) in bracket (Figure 4, Item 8) and shaft (Figure 4, Item 4). Install grease fitting (Figure 4, Item 3) in shaft (Figure 4, Item 4).
0679-6
TM 9-2320-272-23-4
0679
3 12 13 1 4
11
10 9
8 5 7
M6016DAA
Figure 4.
Roller Assembly.
0679-7
TM 9-2320-272-23-4
0679
ASSEMBLY - Continued 8. 9. Align screw holes in roller shaft (Figure 5, Item 3) and roller bracket (Figure 5, Item 4), and install roller shaft in roller bracket. Install two setscrews (Figure 5, Item 5) in roller bracket (Figure 5, Item 4) and shaft (Figure 5, Item 3).
NOTE
Soak felt washers in oil and coat bearings with GAA grease before installation. Steel side of felt washers must be on bearing side on shaft. 10. 11. 12. 13. Install bearings (Figure 5, Item 6) and (Figure 5, Item 8) in roller (Figure 5, Item 7). Install thrust washer (Figure 5, Item 2), felt washer (Figure 5, Item 1), roller (Figure 5, Item 7), and felt washer (Figure 5, Item 1) on roller shaft (Figure 5, Item 3). Install thrust washer (Figure 5, Item 10) and right roller bracket (Figure 5, Item 4) on shaft (Figure 5, Item 11). Install two grease fittings (Figure 5, Item 9) on ends of shaft (Figure 5, Item 11).
0679-8
TM 9-2320-272-23-4
0679
4 3 5
8 7 1 6
4 11
9 10
M6017DAA
Roller Assembly.
0679-9
TM 9-2320-272-23-4
0679
INSTALLATION Install winch roller assembly (Figure 6, Item 5) on winch (Figure 6, Item 1) with 12 lockwashers (Figure 6, Item 2), eight screws (Figure 6, Item 4), and four screws (Figure 6, Item 3).
2 4
2
M6018DAA
Roller Assembly Installation.
Lubricate roller assembly. (Volume 5, WP 0820) Install front winch. (WP 0668)
0679-10
TM 9-2320-272-23-4
0680
FIELD MAINTENANCE FRONT WINCH CONTROL VALVE CABLE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin (Volume 5, WP 0827, Table 1, Item 9) Qty: 1 Cotter Pin (Volume 5, WP 0827, Table 1, Item 333) Qty: 1 Materials/Parts (cont.) Cotter Pin (Volume 5, WP 0827, Table 1, Item 340) Qty: 1 Tiedown Strap (Volume 5, WP 0827, Table 1, Item 375) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0680-1
TM 9-2320-272-23-4
0680
REMOVAL
NOTE
Remove tiedown straps as needed. 1. 2. 3. 4. Remove cotter pin (Figure 1, Item 4), washer (Figure 1, Item 3), and clevis pin (Figure 1, Item 2) from clevis (Figure 1, Item 1). Discard cotter pin. Remove clevis (Figure 1, Item 1) and nut (Figure 1, Item 5) from cable (Figure 1, Item 9). Remove nut (Figure 1, Item 6), washer (Figure 1, Item 7), and cable (Figure 1, Item 9) from bracket (Figure 1, Item 8). Remove washer (Figure 1, Item 11) and nut (Figure 1, Item 10) from cable (Figure 1, Item 9).
10
11
1 2
9 7 8 6 5 4 3
M6021DAA
Figure 1.
Front Winch Control Valve Cable Removal.
0680-2
TM 9-2320-272-23-4
0680
REMOVAL - Continued 5. 6. 7. Remove six screws (Figure 2, Item 11) and shift panel cover (Figure 2, Item 12) from shift panel (Figure 2, Item 3). Remove cotter pin (Figure 2, Item 16), clevis pin (Figure 2, Item 13), washer (Figure 2, Item 14), and cable clevis (Figure 2, Item 15) from lever (Figure 2, Item 2). Discard cotter pin. Remove cotter pin (Figure 2, Item 4), pin (Figure 2, Item 1), washer (Figure 2, Item 17), and lever (Figure 2, Item 2) from shift panel (Figure 2, Item 3). Discard cotter pin.
NOTE
Grommet may remain on cable during removal. Transfer grommet to cable. 8. Remove two nuts (Figure 2, Item 5), screws (Figure 2, Item 10), clamp (Figure 2, Item 9), shim (Figure 2, Item 8), and cable (Figure 2, Item 7) from vehicle.
1 2 17 3 13 14 15 16
4 8 9 12 10 7 5 6
11
M6022DAA
Winch Control Valve Cable.
0680-3
TM 9-2320-272-23-4
0680
INSTALLATION
NOTE
Install tiedown straps as required. 1. 2. Install lever (Figure 3, Item 2) in shift panel (Figure 3, Item 3) with washer (Figure 3, Item 17), pin (Figure 3, Item 1), and cotter pin (Figure 3, Item 4). Bend ends of cotter pin. Ensure grommet (Figure 3, Item 6) is positioned in firewall, and install cable clevis (Figure 3, Item 15) on lever (Figure 3, Item 3) with washer (Figure 3, Item 14), clevis pin, and cotter pin (Figure 3, Item 16). Bend ends of cotter pin. Install shim (Figure 3, Item 8) and cable (Figure 3, Item 7) on shift panel (Figure 3, Item 3) with two screws (Figure 3, Item 10) and two locknuts (Figure 3, Item 5). Install shift panel cover (Figure 3, Item 12) on shift panel (Figure 3, Item 3) with six screws (Figure 3, Item 11).
1 2 17 3 13 14 15 16
3. 4.
4 8 9 12 10 7 5 6
11
M6023DAA
Figure 3. Winch Control Valve Cable.
0680-4
TM 9-2320-272-23-4
0680
NOTE
Place shift lever in NEUTRAL position. 5. 6. 7. 8. 9. Install nut (Figure 4, Item 11) and washer (Figure 4, Item 12) on cable (Figure 4, Item 10) and feed end of cable through bracket (Figure 4, Item 9). Install washer (Figure 4, Item 8), nuts (Figure 4, Items 6 and 7), and clevis (Figure 4, Item 1) on end of cable (Figure 4, Item 10). Position clevis (Figure 4, Item 1) on valve shaft (Figure 4, Item 3) and adjust nuts (Figure 4, Items 6 and 7) until holes in end of cable (Figure 4, Item 10) and shaft align. Install clevis pin (Figure 4, Item 2), washer (Figure 4, Item 4), and cotter pin (Figure 4, Item 5) in clevis (Figure 4, Item 1) and shaft (Figure 4, Item 3). Bend ends of cotter pin. Tighten nuts (Figure 4, Items 6, 7, and 9).
11
12
1 2
10 8 9 7 6 5 4 3
M6024DAA
Figure 4. Winch Control Valve Cable Installation. END OF TASK
0680-5
TM 9-2320-272-23-4
0680
FOLLOW-ON MAINTENANCE Start engine and check winch control valve operation. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0680-6
TM 9-2320-272-23-4
0681
FIELD MAINTENANCE FRONT AND REAR WINCH CONTROL VALVE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Cotter Pin (Volume 5, WP 0827, Table 1, Item 340) Qty: 1 Locknut (Volume 5, WP 0827, Table 1, Item 285) Qty: 3 Locknut (Volume 5, WP 0827, Table 1, Item 297) Qty: 4 O-ring (Volume 5, WP 0827, Table 1, Item 80) Qty: 2 Materials/Parts (cont.) O-ring (Volume 5, WP 0827, Table 1, Item 164) Qty: 1 O-ring (Volume 5, WP 0827, Table 1, Item 364) Qty: 2 References Volume 5, WP 0820 Equipment Condition Parking brake set. (TM 9-2320-272-10) Hydraulic oil reservoir drained. (WP 0703)
0681-1
TM 9-2320-272-23-4
0681
REMOVAL
CAUTION
Plug hydraulic hoses to prevent dirt from entering.
NOTE
All hoses and fittings must be tagged for installation. 1. 2. 3. 4. 5. 6. 7. 8. 9. Disconnect hoses (Figure 1, Items 1, 4, 5, and 6) from control valve (Figure 1, Item 7). Tag for installation. Remove cotter pin (Figure 1, Item 14), washer (Figure 1, Item 15), and clevis pin (Figure 1, Item 3) from cable clevis (Figure 1, Item 2). Discard cotter pin. Remove three locknuts (Figure 1, Item 13), screws (Figure 1, Item 10), and control valve (Figure 1, Item 7) from bracket (Figure 1, Item 12). Discard locknuts. Remove four locknuts (Figure 1, Item 8), screws (Figure 1, Item 11), and bracket (Figure 1, Item 12) from frame (Figure 1, Item 9). Discard locknuts. Remove elbow (Figure 1, Item 20) and adapter (Figure 1, Item 25) from fitting (Figure 1, Item 19) and elbow (Figure 1, Item 26). Remove fittings (Figure 1, Items 16 and 19) and elbows (Figure 1, Items 18 and 26) from control valve (Figure 1, Item 7). Remove four o-rings (Figure 1, Item 17) from fittings (Figure 1, Items 16 and 19) and elbows (Figure 1, Items 18 and 26). Discard o-rings. Remove plug (Figure 1, Item 21), spring (Figure 1, Item 23), and relief valve (Figure 1, Item 24) from control valve (Figure 1, Item 7). Remove o-ring (Figure 1, Item 22) from plug (Figure 1, Item 21). Discard o-ring.
0681-2
TM 9-2320-272-23-4
0681
REMOVAL - Continued
4 1 2 3 5
15 6 10 8 13 12 9 11 19 16 18 17 17 21 22 23 24 25 7 26 17
M6025DAA
14
20
17
Front and Rear Winch Control Valve Removal.
0681-3
TM 9-2320-272-23-4
0681
INSTALLATION 1. 2. 3. 4. 5. Install o-ring (Figure 2, Item 22) on plug (Figure 2, Item 21) and install relief valve (Figure 2, Item 24), spring (Figure 2, Item 23), and plug (Figure 2, Item 21) in control valve (Figure 2, Item 7). Install four o-rings (Figure 2, Item 17) and fittings (Figure 2, Items 16, 18, 19, and 26) on control valve (Figure 2, Item 7). Install fittings (Figure 2, Items 20 and 25) on fittings (Figure 2, Items 19 and 26). Install bracket (Figure 2, Item 12) on frame (Figure 2, Item 9) with four screws (Figure 2, Item 11) and locknuts (Figure 2, Item 8). Install control valve (Figure 2, Item 7) on bracket (Figure 2, Item 12) with three screws (Figure 2, Item 10) and locknuts (Figure 2, Item 13).
WARNING
Do not cross hoses during installation. Failure to comply may result in injury or death to personnel. 6. 7. Install hoses (Figure 2, Items 1, 4, 5, and 6) on control valve (Figure 2, Item 7). Install cable clevis (Figure 2, Item 2) on control valve (Figure 2, Item 7) with clevis pin (Figure 2, Item 3), washer (Figure 2, Item 15), and cotter pin (Figure 2, Item 14). Bend ends of cotter pin.
0681-4
TM 9-2320-272-23-4
0681
4 1 2 3 5
15 6 10 8 13 12 9 11 19 16 18 17 17 21 22 23 24 25 7 26 17
M6026DAA
14
20
17
Figure 2. Front and Rear Winch Control Valve Installation. END OF TASK
0681-5
TM 9-2320-272-23-4
0681
FOLLOW-ON MAINTENANCE 1. 2. Fill hydraulic oil reservoir. (Volume 5, WP 0820) Start engine and check hydraulic pump operation. (TM 9-2320-272-10)
0681-6
TM 9-2320-272-23-4
0682
FIELD MAINTENANCE REAR WINCH HYDRAULIC MOTOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Wrench, Torque, Click, Ratcheting, 1/2" Drive, 250 Ft-Lb (Volume 5, WP 0826, Table 1, Item 63) Materials/Parts Sealing Compound (Volume 5, WP 0825, Table 1, Item 56) Tape, Antiseizing (Volume 5, WP 0825, Table 1, Item 65) Cotter Pin (Volume 5, WP 0827, Table 1, Item 352) Qty: 1 Locknut (Volume 5, WP 0827, Table 1, Item 289) Qty: 4 Lockwasher (Volume 5, WP 0827, Table 1, Item 2) Qty: 6 Lockwasher (Volume 5, WP 0827, Table 1, Item 186) Qty: 5 Rod Seal (Volume 5, WP 0827, Table 1, Item 63) Qty: 2 Materials/Parts (cont.) O-ring (Volume 5, WP 0827, Table 1, Item 368) Qty: 1 O-ring (Volume 5, WP 0827, Table 1, Item 361) Qty: 1 Personnel Required (2) References Volume 5, WP 0820 Equipment Condition Parking brake set. (TM 9-2320-272-10) Hydraulic oil reservoir drained. (WP 0703)
0682-1
TM 9-2320-272-23-4
0682
REMOVAL 1. 2. 3. Remove five screws (Figure 1, Item 4), lockwashers (Figure 1, Item 5), washers (Figure 1, Item 6), and cover (Figure 1, Item 3) from floor plate (Figure 1, Item 15). Discard lockwashers. Remove four screws (Figure 1, Item 2), washers (Figure 1, Item 1), and floor plate (Figure 1, Item 15) from frame (Figure 1, Item 7). Remove two locknuts (Figure 1, Item 8), screws (Figure 1, Item 11), and washers (Figure 1, Item 10) from front bracket (Figure 1, Item 9) and frame (Figure 1, Item 7). Discard locknuts.
NOTE
Have drainage container ready to catch oil. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. 4. 5. 6. 7. Disconnect hose connector (Figure 1, Item 16) from elbow (Figure 1, Item 21). Remove elbow (Figure 1, Item 21), adapter (Figure 1, Item 20), and valve (Figure 1, Item 19) from elbow (Figure 1, Item 18). Tag adapter and valve for installation. Rotate elbow (Figure 1, Item 18) upward on pipe nipple (Figure 1, Item 17) to allow removal of front bracket (Figure 1, Item 9). Remove three screws (Figure 1, Item 12), lockwashers (Figure 1, Item 13), and front bracket (Figure 1, Item 9) from winch motor (Figure 1, Item 14).
0682-2
TM 9-2320-272-23-4
0682
REMOVAL - Continued
2 1 3
5 6
15
12
13 14
11 10 9
16 21 17 9 8 7
20 19 18
M6038DAA
Figure 1. Rear Winch Hydraulic Motor Removal. 0682-3
TM 9-2320-272-23-4
0682
REMOVAL - Continued 8. 9. Remove elbow (Figure 2, Item 7) and pipe nipple (Figure 2, Item 6) from winch motor (Figure 2, Item 8). Remove 12 screws (Figure 2, Item 2), washers (Figure 2, Item 3), and six clamps (Figure 2, Item 4) from hydraulic motor (Figure 2, Item 8).
NOTE
Tag hydraulic hoses for installation. 10. 11. 12. 13. 14. 15. 16. Remove three hydraulic hoses (Figure 2, Item 1) and o-rings (Figure 2, Item 5) from hydraulic motor (Figure 2, Item 8). Discard o-rings. Disconnect hydraulic hose (Figure 2, Item 11) from elbow (Figure 2, Item 10) on winch motor o(Figure 2, Item 8). Remove elbow (Figure 2, Item 10) and o-ring (Figure 2, Item 9) from winch motor (Figure 2, Item 8). Discard o-ring. Disconnect two hose connectors (Figure 2, Items 31 and 32) from tee (Figure 2, Item 33). Loosen setscrew (Figure 2, Item 14) until flush with front coupling hub (Figure 2, Item 18). Remove tee (Figure 2, Item 33), adapter (Figure 2, Item 30), valve (Figure 2, Item 29), and elbow (Figure 2, Item 7) from pipe nipple (Figure 2, Item 6). Tag valve for installation. Remove two locknuts (Figure 2, Item 27), screws (Figure 2, Item 25), and washers (Figure 2, Item 26) from frame crossmember (Figure 2, Item 24) and rear bracket (Figure 2, Item 28). Discard locknuts.
NOTE
Assistant will help with Step (17). 17. 18. 19. 20. 21. 22. Remove winch motor (Figure 2, Item 8) and rear bracket (Figure 2, Item 28) from frame crossmember (Figure 2, Item 24). Remove key (Figure 2, Item 13) from winch motor shaft (Figure 2, Item 12). Remove six screws (Figure 2, Item 16), lockwashers (Figure 2, Item 15), and rear bracket (Figure 2, Item 28) from winch motor (Figure 2, Item 8). Discard lockwashers. Remove pipe nipple (Figure 2, Item 6) from winch motor (Figure 2, Item 8). Tag pipe nipple for installation. Remove cotter pin (Figure 2, Item 22) and shear pin (Figure 2, Item 23) from rear coupling hub (Figure 2, Item 20). Discard cotter pin. Remove coupling (Figure 2, Item 19) from winch driveshaft (Figure 2, Item 21).
0682-4
TM 9-2320-272-23-4
0682
REMOVAL - Continued
1 2
2 3
3 4 4 4 5 11 10
1 2 3
4 9 8 7 5
8 28 31 30 29 28 27 26 33 6 7 32 12 13 14 15
17
18
19
20 21
16 23 24 25 26
M6039DAA
22
Rear Winch Hydraulic Motor Hoses and Fittings Removal.
0682-5
TM 9-2320-272-23-4
0682
INSTALLATION 1. Align holes in rear coupling hub (Figure 3, Item 20) and driveshaft (Figure 3, Item 21) and install coupling (Figure 3, Item 19) on winch driveshaft with shear pin (Figure 3, Item 23) and cotter pin (Figure 3, Item 22).
NOTE
Wrap all male pipe threads with antiseize tape before installation. 2. Install rear bracket (Figure 3, Item 28) on winch motor (Figure 3, Item 8) with six lockwashers (Figure 3, Item 15) and screws (Figure 3, Item 16). Tighten screws 60 to 70 lb-ft (81 to 95 Nm).
NOTE
Assistant will help with Step (3). 3. 4. Place key (Figure 3, Item 13) in slot of winch motor shaft (Figure 3, Item 12) and install winch motor (Figure 3, Item 8) on coupling (Figure 3, Item 19). Ensure key is visible in setscrew hole (Figure 3, Item 17). Install rear bracket (Figure 3, Item 28) on frame crossmember (Figure 3, Item 24) with four washers (Figure 3, Item 26), two screws (Figure 3, Item 25), and two locknuts (Figure 3, Item 27). Tighten locknuts 60 to 70 lb-ft (81 to 95 Nm). Install pipe nipple (Figure 3, Item 6), elbow (Figure 3, Item 7), valve (Figure 3, Item 29), adapter (Figure 3, Item 30), and tee (Figure 3, Item 33) on winch motor (Figure 3, Item 8). Connect two hose connectors (Figure 3, Items 31 and 32) to tee (Figure 3, Item 33). Apply sealing compound to threads of setscrew (Figure 3, Item 14) and install in hole (Figure 3, Item 17) in front coupling hub (Figure 3, Item 18). Install elbow (Figure 3, Item 10) on winch motor (Figure 3, Item 8) with o-ring (Figure 3, Item 9). Connect hydraulic hose (Figure 3, Item 11) on elbow (Figure 3, Item 10). Connect three hydraulic hoses (Figure 3, Item 1) to winch motor (Figure 3, Item 8) with o-rings (Figure 3, Item 5), six clamps (Figure 3, Item 4), 12 washers (Figure 3, Item 3), and screws (Figure 3, Item 2). Install pipe nipple (Figure 3, Item 21) and elbow (Figure 3, Item 22) on winch motor (Figure 3, Item 18) with elbow pointed up.
5. 6. 7. 8. 9. 10.
11.
0682-6
TM 9-2320-272-23-4
0682
1 2
2 3
3 4 4 4 5 11 10
1 2 3
4 9 8 7 5
8 28 31 30 29 28 27 26 33 6 7 32 12 13 14 15
17
18
19
20 21
16 23 24 25 26
M6040DAA
22
Figure 3. Rear Winch Hydraulic Motor Hoses and Fittings Installation.
0682-7
TM 9-2320-272-23-4
0682
INSTALLATION - Continued 12. Install front bracket (Figure 4, Item 9) on winch motor (Figure 4, Item 14) with three lockwashers (Figure 4, Item 13) and screws (Figure 4, Item 12). Tighten screws 60 to 70 lb-ft (81 to 95 Nm). Turn elbow (Figure 4, Item 18) to point left. Install valve (Figure 4, Item 19), adapter (Figure 4, Item 20), and elbow (Figure 4, Item 21) on elbow (Figure 4, Item 18). Connect hose connector (Figure 4, Item 16) to elbow (Figure 4, Item 21). Install front bracket (Figure 4, Item 9) on frame (Figure 4, Item 7) with two washers (Figure 4, Item 10), screws (Figure 4, Item 11), and locknuts (Figure 4, Item 8). Tighten locknuts 60 to 70 lb-ft (81 to 95 Nm). Install floor plate (Figure 4, Item 15) on frame (Figure 4, Item 7) with four washers (Figure 4, Item 1) and screws (Figure 4, Item 2). Tighten screws 60 to 70 lb-ft (81 to 95 Nm). Install cover (Figure 4, Item 3) on frame (Figure 4, Item 7) with five washers (Figure 4, Item 6), lockwashers (Figure 4, Item 5), and screws (Figure 4, Item 4). Tighten screws 60 to 70 lb-ft (81 to 95 Nm).
13. 14. 15. 16. 17.
0682-8
TM 9-2320-272-23-4
0682
2 1 3
5 6
15
12
13
14
11 10 9 16 21 9 17 8 7
20 19 18
M6041DAA
Rear Winch Hydraulic Motor Installation.
0682-9
TM 9-2320-272-23-4
0682
FOLLOW-ON MAINTENANCE 1. 2. Fill hydraulic oil reservoir to proper level. (Volume 5, WP 0820) Check rear winch hydraulic motor for proper operation. (TM 9-2320-272-10)
0682-10
TM 9-2320-272-23-4
0683
FIELD MAINTENANCE FRONT WINCH HYDRAULIC PUMP REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 289) Qty: 2 Lockwasher (Volume 5, WP 0827, Table 1, Item 186) Qty: 4 Lockwasher (Volume 5, WP 0827, Table 1, Item 405) Qty: 4 Materials/Parts (cont.) O-ring (Volume 5, WP 0827, Table 1, Item 360) Qty: 1 O-ring (Volume 5, WP 0827, Table 1, Item 361) Qty: 1 References Volume 5, WP 0820 Equipment Condition Parking brake set. (TM 9-2320-272-10) Hydraulic oil reservoir drained. (TM 9-2320-272-10)
0683-1
TM 9-2320-272-23-4
0683
REMOVAL 1. 2. Remove setscrew (Figure 1, Item 1) and driveshaft (Figure 1, Item 14) from pump shaft (Figure 1, Item 13). Remove four screws (Figure 1, Item 7), lockwashers (Figure 1, Item 16), two pipe flange swivels (Figure 1, Item 5), tube (Figure 1, Item 6), and o-ring (Figure 1, Item 15) from hydraulic pump (Figure 1, Item 4). Discard o-ring and lockwashers. Remove four screws (Figure 1, Item 9), lockwashers (Figure 1, Item 10), two pipe flange swivels (Figure 1, Item 11), tube (Figure 1, Item 8), and o-ring (Figure 1, Item 17) from hydraulic pump (Figure 1, Item 4). Discard o-ring and lockwashers. Remove two screws (Figure 1, Item 2), locknuts (Figure 1, Item 3), and hydraulic pump (Figure 1, Item 4) from pump bracket (Figure 1, Item 12). Discard locknuts.
3.
4.
1 14 2 3
13 12 11 11 10 9 16 17 5 15 5
7 8 6
M6019DAA
Figure 1. Front Winch Hydraulic Motor Removal. END OF TASK
0683-2
TM 9-2320-272-23-4
0683
INSTALLATION 1. 2. 3. 4. 5. Install pump (Figure 2, Item 4) on bracket (Figure 2, Item 12) with two screws (Figure 2, Item 2) and locknuts (Figure 2, Item 3). Install o-ring (Figure 2, Item 15), two pipe flange swivels (Figure 2, Item 5), and tube (Figure 2, Item 6) on pump (Figure 2, Item 4) with four lockwashers (Figure 2, Item 16) and screws (Figure 2, Item 7). Install o-ring (Figure 2, Item 17), two pipe flange swivels (Figure 2, Item 11), and tube (Figure 2, Item 8) on pump (Figure 2, Item 4) with four lockwashers (Figure 2, Item 10) and screws (Figure 2, Item 9). Ensure key is in keyway and connect driveshaft (Figure 2, Item 14) to pump shaft (Figure 2, Item 13). Install setscrew (Figure 2, Item 1) in driveshaft (Figure 2, Item 14) and tighten.
1 14 2 3
13 12 11 11 10 9 16 17 5 15 5
7 8 6
M6020DAA
Front Winch Hydraulic Motor Installation.
0683-3
TM 9-2320-272-23-4
0683
FOLLOW-ON MAINTENANCE 1. 2. Fill hydraulic tank. (TM 9-2320-272-10) Operate winch system and check for leaks. (TM 9-2320-272-10)
0683-4
TM 9-2320-272-23-4
0684
FIELD MAINTENANCE FRONT WINCH CABLE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Front winch cable unwound. (TM 9-2320-272-10) Cable chain and hook removed. (WP 0674)
0684-1
TM 9-2320-272-23-4
0684
REMOVAL
WARNING
Wear hand protection when handling winch cable. Do not handle cable with bare hands. Broken wires may be sharp. Failure to comply may result in injury or death to personnel. 1. Remove setscrew (Figure 1, Item 1) and winch cable (Figure 1, Item 4) from hole (Figure 1, Item 3) in winch drum (Figure 1, Item 2).
NOTE
Perform Step (2) if front winch is equipped with level wind and tensioner. 2. Pull winch cable (Figure 1, Item 4) out at side roller (Figure 1, Item 9), over level wind pulley (Figure 1, Item 6), down through tensioner sheaves (Figure 1, Item 7), and out of rollers (Figure 1, Items 8 and 9).
0684-2
TM 9-2320-272-23-4
0684
REMOVAL - Continued
4 3 2 5 6
8 4 7
M5242DAA
Front Winch Cable Removal.
0684-3
TM 9-2320-272-23-4
0684
INSTALLATION
NOTE
Perform Step (1) if front winch is equipped with level wind and tensioner. 1. Thread winch cable (Figure 2, Item 4) into center of rollers (Figure 2, Items 8 and 9), tensioner sheaves (Figure 2, Item 7), under level wind pulley plate (Figure 2, Item 5), and over level wind pulley (Figure 2, Item 6). Insert winch cable (Figure 2, Item 4) in hole (Figure 2, Item 3) of winch drum (Figure 2, Item 2) and install setscrew (Figure 2, Item 1).
2.
0684-4
TM 9-2320-272-23-4
0684
4 3 2 5 6
8 4 7
M5243DAA
Front Winch Cable Installation.
0684-5
TM 9-2320-272-23-4
0684
FOLLOW-ON MAINTENANCE 1. 2. Wind cable on drum. (TM 9-2320-272-10) Install cable chain and hook. (WP 0674)
0684-6
TM 9-2320-272-23-4
0685
FIELD MAINTENANCE FRONT WINCH HYDRAULIC HOSE AND TUBE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Locknut (Volume 5, WP 0827, Table 1, Item 430) Qty: 2 Tiedown Straps (Volume 5, WP 0827, Table 1, Item 379) Qty: 5 References Volume 5, WP 0820 Equipment Condition Parking brake set. (TM 9-2320-272-10) Hydraulic oil reservoir drained. (WP 0703)
0685-1
TM 9-2320-272-23-4
0685
REMOVAL
CAUTION
Plug all openings to prevent dirt from entering and damaging components.
NOTE
Remove and discard tiedown straps holding hoses to vehicle. Have drainage container ready to catch oil. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. Perform Steps (1) through (4) for all vehicles except M936/A1/A2. 1. 2. 3. 4. Holding filter adapter (Figure 1, Item 13), loosen hose nut (Figure 1, Item 15) and disconnect hose (Figure 1, Item 12) from hydraulic oil reservoir (Figure 1, Item 1). Remove nut (Figure 1, Item 14), screw (Figure 1, Item 4), and clamp (Figure 1, Item 5) from mounting bracket (Figure 1, Item 11). Loosen hose nut (Figure 1, Item 3) and disconnect hose (Figure 1, Item 7) from reservoir elbow (Figure 1, Item 2). Remove hose (Figure 1, Item 7) from reservoir (Figure 1, Item 1).
NOTE
Clamp brackets remain attached to frame rail. 5. Remove two locknuts (Figure 1, Item 8), screws (Figure 1, Item 6), and two pairs of hose clamps (Figure 1, Item 7) from right frame rail (Figure 1, Item 10) and two hydraulic hoses (Figure 1, Item 9). Discard locknuts.
0685-2
TM 9-2320-272-23-4
0685
REMOVAL - Continued
1 15 2 14 13 12 3
11 4 5
6 10
8
M6029DAA
Figure 1.
Hydraulic Oil Reservoir Hoses Removal.
0685-3
TM 9-2320-272-23-4
0685
REMOVAL - Continued
NOTE
Tag hoses for installation. 6. Using two wrenches (Figure 2, Item 2), disconnect swivel flare nut (Figure 2, Item 1) and hose end (Figure 2, Item 3) and remove four hoses (Figure 2, Item 4) and two tubes (Figure 2, Items 5 and 6).
0685-4
TM 9-2320-272-23-4
0685
REMOVAL - Continued
2 1 3
5
M6030DAA
Figure 2. Front Winch Hydraulic Hoses and Tubes Removal.
0685-5
TM 9-2320-272-23-4
0685
REMOVAL - Continued
NOTE
Perform Steps (7) and (8) for all vehicles except M936/A1/A2. 7. Using wrench to prevent adapter (Figure 3, Item 2) from turning, disconnect hose (Figure 3, Item 1) from adapter on filter (Figure 3, Item 3) and from control valve (Figure 3, Item 4).
4 3
M9563DAA
Figure 3.
0685-6
TM 9-2320-272-23-4
0685
REMOVAL - Continued 8. Disconnect two tubes (Figure 4, Items 3 and 4) from adapters (Figure 4, Items 2 and 5) on hydraulic pump (Figure 4, Item 1).
1
2 5 4 3
M6031DAA
0685-7
TM 9-2320-272-23-4
0685
INSTALLATION 1. Connect tubes (Figure 5, Items 3 and 4) to adapters (Figure 5, Items 2 and 5) on hydraulic pump (Figure 5, Item 1).
1
2 5 4 3
M6032DAA
Figure 5.
Hydraulic Oil Reservoir Hoses Installation.
0685-8
TM 9-2320-272-23-4
0685
NOTE
Perform Step (2) for all vehicles except M936/A1/A2. 2. Connect hose (Figure 6, Item 1) to control valve (Figure 6, Item 4) and adapter (Figure 6, Item 2) on filter (Figure 6, Item 3).
4 3
M9564DAA
Figure 6.
Hydraulic Oil Reservoir Hoses Installation.
0685-9
TM 9-2320-272-23-4
0685
NOTE
Perform Steps (3) and (4) for all vehicles except M936/A1/A2. 3. 4. Connect hydraulic hose (Figure 7, Item 6) to elbow (Figure 7, Item 2) and adapter (Figure 7, Item 1). Install hose (Figure 7, Item 6) on mounting bracket (Figure 7, Item 5) with clamp (Figure 7, Item 4), screw (Figure 7, Item 3), and nut (Figure 7, Item 7).
0685-10
TM 9-2320-272-23-4
0685
3
M6033DAA
Figure 7.
Front Winch Hydraulic Hoses and Tubes Installation.
0685-11
TM 9-2320-272-23-4
0685
INSTALLATION - Continued 5. 6. 7. Using care not to bend tube (Figure 8, Item 3), connect hose (Figure 8, Item 4) to elbow (Figure 8, Item 5) and tube (Figure 8, Item 2). Using care not to bend tube (Figure 8, Item 2), connect hose (Figure 8, Item 1) to tube and control valve elbow (Figure 8, Item 15). Connect two hose ends (Figure 8, Item 16) as tagged to two control valve elbows (Figure 8, Item 14).
WARNING
Do not cross hoses during installation. Failure to comply may result in injury or death to personnel. 8. 9. 10. Connect two hose ends (Figure 8, Item 6) to two elbows (Figure 8, Item 7). Position two pairs of clamps (Figure 8, Item 9) on hoses (Figure 8, Item 12) and install clamps on two brackets (Figure 8, Item 13) with two screws (Figure 8, Item 8) and locknuts (Figure 8, Item 10). Install six tiedown straps (Figure 8, Item 11) as necessary over two hoses (Figure 8, Item 12).
0685-12
TM 9-2320-272-23-4
0685
8 6 13 10
12 7 11
14 16
1 15
2
M6033-1DAA
Hydraulic Tubes and Hoses Installation.
0685-13
TM 9-2320-272-23-4
0685
FOLLOW-ON MAINTENANCE 1. 2. Fill hydraulic oil reservoir. (Volume 5, WP 0820) Start engine. Operate winch and check for leaks and proper operation. (TM 9-2320-272-10)
0685-14
TM 9-2320-272-23-4
0686
FIELD MAINTENANCE BOOM REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Chain Assembly (Volume 5, WP 0826, Table 1, Item 15) Lifting Device Multiplier, Torque (Volume 5, WP 0826, Table 1, Item 35) Wrench, Torque, Click, Ratcheting, 1/2" Drive, 250 Ft-Lb (Volume 5, WP 0826, Table 1, Item 63) Wrench, Torque, Click, Ratcheting, 3/8" Drive, 75 Ft-Lb (Volume 5, WP 0826, Table 1, Item 62) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Materials/Parts (cont.) Locknut (Volume 5, WP 0827, Table 1, Item 324) Qty: 1 Lockwasher (Volume 5, WP 0827, Table 1, Item 405) Qty: 2 Personnel Required (2) References Volume 5, WP 0820 Equipment Condition Parking brake set. (TM 9-2320-272-10) Boom floodlight wire removed. (Volume 2, WP 0331) Hydraulic oil reservoir drained. (WP 0703) Hoist winch removed. (WP 0696)
0686-1
TM 9-2320-272-23-4
0686
REMOVAL
WARNING
CAUTION
When disconnecting hydraulic lines and hoses, plug all openings to prevent dirt from entering and causing internal damage to parts.
NOTE
Have drainage container ready to catch oil. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. Tag hoses for installation. 1. 2. 3. 4. 5. Disconnect cylinder extension hose (Figure 1, Item 6) and retracting hose (Figure 1, Item 5) from two boom adapter elbows (Figure 1, Item 4). Secure inner boom (Figure 1, Item 18) to outer boom (Figure 1, Item 3) with utility chain (Figure 1, Item 2) to prevent inner boom movement during hoisting operation. Attach two utility chains (Figure 1, Item 2) to outer boom (Figure 1, Item 3). Raise outer boom (Figure 1, Item 3) until weight of boom is fully supported and elevating cylinder retaining pins (Figure 1, Item 17) are free. Remove two screws (Figure 1, Item 15), lockwashers (Figure 1, Item 16), and retaining pins (Figure 1, Item 17) from outer boom (Figure 1, Item 3) and two elevating cylinders (Figure 1, Item 14). Discard lockwashers.
WARNING
Before hoisting outer boom away from wrecker, ensure inner boom is properly secured to outer boom as outlined in Step (2). Failure to comply may result in injury or death to personnel. 6. 7. 8. 9. Remove grease fittings (Figure 1, Items 7 and 13) from pivot pin (Figure 1, Item 8). Remove locknut (Figure 1, Item 12), pivot pin (Figure 1, Item 8), two sleeve bearings (Figure 1, Item 10), and crane sheave (Figure 1, Item 11) from turntable (Figure 1, Item 9). Discard locknut. Using lifting device (Figure 1, Item 1) and utility chains (Figure 1, Item 2), with assistant guiding movement, move outer boom (Figure 1, Item 3) off vehicle and onto jack stands. Remove utility chains from outer boom (Figure 1, Item 3).
0686-2
TM 9-2320-272-23-4
0686
REMOVAL - Continued
18 2
2 3
17 16 15
5 14 6 7
8 9
13 11 12 10
10
M6064DAA
Boom Removal.
0686-3
TM 9-2320-272-23-4
0686
INSTALLATION
WARNING
Before hoisting outer boom away from wrecker, ensure inner boom is properly secured to outer boom as outlined in Step (2). Failure to comply may result in injury or death to personnel.
NOTE
If installing boom assembly, use hardware from old boom. 1. 2. 3. 4. Install utility chain (Figure 2, Item 2) to secure inner boom (Figure 2, Item 18) to outer boom (Figure 2, Item 3). Attach two utility chains (Figure 2, Item 2) on outer boom (Figure 2, Item 3). Hoist outer boom (Figure 2, Item 3) over wrecker and position on turntable (Figure 2, Item 9). Assemble two sleeve bearings (Figure 2, Item 10) and sheave (Figure 2, Item 11), align sheave with holes in turntable (Figure 2, Item 9) and outer boom (Figure 2, Item 3), and install boom on turntable with pivot pin (Figure 2, Item 8) and locknut (Figure 2, Item 12). Tighten locknut 800 to 1,000 lb-ft (1,185 to 1,356 Nm). Install grease fittings (Figure 2, Items 7 and 13) on pivot pin (Figure 2, Item 8). Connect two elevating cylinders (Figure 2, Item 14) to boom (Figure 2, Item 3) with two retaining pins (Figure 2, Item 17), lockwashers (Figure 2, Item 16), and screws (Figure 2, Item 15). Tighten screws 44 to 61 lb-ft (60 to 83 Nm). Using lifting device and utility chains, lift outer boom (Figure 2, Item 3) and disconnect shipper braces from boom. Connect cylinder extension hose (Figure 2, Item 6) and retracting hose (Figure 2, Item 5) to two boom adapter elbows (Figure 2, Item 4). Remove utility chains from outer boom (Figure 2, Item 3).
5. 6.
7. 8. 9.
0686-4
TM 9-2320-272-23-4
0686
18 2
2 3
17 16 15
5 14 6 7
8 9
13 11 12 10
10
M6065DAA
Boom Installation.
0686-5
TM 9-2320-272-23-4
0686
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install boom floodlight wire. (Volume 2, WP 0331) Fill hydraulic oil reservoir to proper level. (Volume 5, WP 0820) Lubricate boom. (Volume 5, WP 0820) Install hoist winch. (WP 0696) Operate boom through full range of motion and check for leaks and proper movement. (TM 9-2320-272-10)
0686-6
TM 9-2320-272-23-4
0687
FIELD MAINTENANCE INNER BOOM REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Chain Assembly (Volume 5, WP 0826, Table 1, Item 15) Lifting Device Materials/Parts Cotter Pin (Volume 5, WP 0827, Table 1, Item 380) Qty: 1 Lockwasher (Volume 5, WP 0827, Table 1, Item 405) Qty: 8 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Boom removed. (WP 0686)
0687-1
TM 9-2320-272-23-4
0687
REMOVAL
WARNING
Assistant must remain at crane controls until removal operation is completed. Injury to personnel may result if boom control lever is accidentally engaged while work is being done between raised boom and swivel base. Failure to comply may result in injury or death to personnel. All personnel must stand clear during hoisting operations. A snapped cable, or swinging or shifting load, may occur. Failure to comply may result in injury or death to personnel.
NOTE
Extension cylinder will be removed and installed with the inner boom during this procedure. 1. 2. Remove cotter pin (Figure 1, Item 3) and pin (Figure 1, Item 2) from extension cylinder (Figure 1, Item 4) and outer boom (Figure 1, Item 1). Discard cotter pin. Remove eight screws (Figure 1, Item 6), lockwashers (Figure 1, Item 7), and two boom stops (Figure 1, Item 8) from outer boom (Figure 1, Item 1). Discard lockwashers.
WARNING
Inner boom must be supported at sheave to prevent tilting until hoist chain can be properly positioned around inner boom. Failure to comply may result in injury or death to personnel. 3. 4. Attach lifting device (Figure 1, Item 10) to sheave (Figure 1, Item 9) of inner boom (Figure 1, Item 13). While assistant monitors and adjusts lifting device (Figure 1, Item 10), slowly pull inner boom (Figure 1, Item 13) out of outer boom (Figure 1, Item 1) until utility chain (Figure 1, Item 12) can be positioned around inner boom.
NOTE
If only one lifting device is available, support must be provided under sheave end of inner boom while transferring lifting hook to utility chain on inner boom. 5. 6. Attach lifting device (Figure 1, Item 10) to utility chain (Figure 1, Item 12) on inner boom (Figure 1, Item 13) and remove inner boom from outerboom (Figure 1, Item 1). Place inner boom (Figure 1, Item 13) on jack stands (Figure 1, Item 5) and remove lifting device (Figure 1, Item 10) and utility chain (Figure 1, Item 12) from inner boom.
0687-2
TM 9-2320-272-23-4
0687
REMOVAL - Continued
10 11 9 12 1 13
8 7
5
Figure 1. END OF TASK Inner Boom Removal.
M6066DAA
0687-3
TM 9-2320-272-23-4
0687
INSTALLATION 1. Attach utility chain (Figure 2, Item 12) to straddle balance point of inner boom (Figure 2, Item 13).
NOTE
Assistant will help with Steps (2) through (5). Ensure pin hole in extension cylinder is parallel to top surface of inner boom. 2. Attach lifting device (Figure 2, Item 10) to chain (Figure 2, Item 12), align inner boom (Figure 2, Item 13) with outer boom (Figure 2, Item 1) and start inner boom into outer boom.
NOTE
If a second lifting device is not available, use sheave end of inner boom to permit transfer of chain and lifting device. 3. 4. 5. Remove chain (Figure 2, Item 12) from inner boom (Figure 2, Item 13). Attach utility chain (Figure 2, Item 12) and lifting device (Figure 2, Item 10) to sheave (Figure 2, Item 9) of inner boom (Figure 2, Item 13). While adjusting position of sheave (Figure 2, Item 9) end of inner boom (Figure 2, Item 13), slide inner boom into outer boom (Figure 2, Item 1) until holes in front of outer boom and extension cylinder (Figure 2, Item 4) align. Install extension cylinder (Figure 2, Item 4) on outer boom (Figure 2, Item 1) with pin (Figure 2, Item 2) and cotter pin (Figure 2, Item 3). Remove lifting device (Figure 2, Item 10) and chain (Figure 2, Item 12) from sheave (Figure 2, Item 9). Install two boom stops (Figure 2, Item 8) on outer boom (Figure 2, Item 1) with eight lockwashers (Figure 2, Item 7) and screws (Figure 2, Item 6).
6. 7. 8.
0687-4
TM 9-2320-272-23-4
0687
10 11 9 12 1 13
8 7
5
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install boom. (WP 0686) Check boom roller lateral and vertical adjustment. (WP 0688) Inner Boom Installation.
M6067DAA
0687-5/6 blank
TM 9-2320-272-23-4
0688
FIELD MAINTENANCE BOOM ROLLER REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Press, Arbor, Hand Operated (Volume 5, WP 0826, Table 1, Item 39) Materials/Parts Cleaning Compound, Solvent (Volume 5, WP 0825, Table 1, Item 16, 17) Lockwasher (Volume 5, WP 0827, Table 1, Item 405) Qty: 8 Lockwasher (Volume 5, WP 0827, Table 1, Item 408) Qty: 6 Woodruff Key (Volume 5, WP 0827, Table 1, Item 416) Qty: 2 References Volume 5, WP 0819 Equipment Condition Parking brake set. (TM 9-2320-272-10) Inner boom removed. (WP 0687)
0688-1
TM 9-2320-272-23-4
0688
REMOVAL
NOTE
Both boom rollers are removed in the same way with boom on or off the vehicle. This procedure applies to the bottom boom roller with inner boom removed. 1. 2. 3. Remove six screws (Figure 1, Item 2), lockwashers (Figure 1, Item 3), and roller (Figure 1, Item 4) from outer boom (Figure 1, Item 1). Discard lockwashers. Thoroughly clean exterior of boom roller (Figure 1, Item 4). Remove eight screws (Figure 1, Item 5), lockwashers (Figure 1, Item 6), left and right mounting caps (Figure 1, Item 7), and four shims (Figure 1, Item 8) from boom roller frame (Figure 1, Item 9). Discard lockwashers. Remove two rollers (Figure 1, Item 10) and roller shaft (Figure 1, Item 13) from frame (Figure 1, Item 9). Remove two rollers (Figure 1, Item 10) from roller shaft (Figure 1, Item 13). Using an arbor press, remove roller bearings (Figure 1, Item 11) from two rollers (Figure 1, Item 10). Remove two woodruff keys (Figure 1, Item 12) from roller shaft (Figure 1, Item 13). Discard woodruff keys.
4. 5. 6. 7.
0688-2
TM 9-2320-272-23-4
0688
REMOVAL - Continued
4 2 3
9 7 5 6 8
10
11
13
12
12
11
10
M6070DAA
Boom Roller Removal.
0688-3
TM 9-2320-272-23-4
0688
INSTALLATION
WARNING
Solvent cleaning compound is flammable and toxic. Do not use near an open flame and always have a fire extinguisher nearby when solvents are used. Use only in well-ventilated places, wear protective clothing, and dispose of cleaning rags in approved container. Failure to comply may result in damage to equipment, injury, or death to personnel. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Clean all boom roller parts with solvent cleaning compound (Volume 5, WP 0819). Inspect roller bearings (Figure 2, Item 7) and rollers (Figure 2, Item 6) for pitting and scoring. Replace bearings or rollers (Figure 2, Item 6) if pitted or scored. Inspect boom roller frame (Figure 2, Item 1) and mounting caps (Figure 2, Item 3) for cracks or damaged threads. Replace roller frame or mounting caps if cracked or threads are damaged. Inspect roller shaft (Figure 2, Item 9) for scoring and breaks. Replace roller shaft if scored or broken. Using arbor press, install two roller bearings (Figure 2, Item 7) on rollers (Figure 2, Item 6). Install two woodruff keys (Figure 2, Item 8) in roller shaft (Figure 2, Item 9). Install two rollers (Figure 2, Item 6) with bearings (Figure 2, Item 7) on roller shaft (Figure 2, Item 9). Position rollers (Figure 2, Item 6) and shaft (Figure 2, Item 9) as an assembly in frame (Figure 2, Item 1). Position left and right mounting caps (Figure 2, Item 3) over shims (Figure 2, Item 2) on frame (Figure 2, Item 1). Measure clearance between mounting caps (Figure 2, Item 3) and rollers (Figure 2, Item 6). Clearance should be 0.062 to 0.125 in. (1.6 to 3.2 mm). If clearance is more than above, remove one or more shims (Figure 2, Item 2). If clearance is less than allowable, add one or more shims. Install left and right mounting caps (Figure 2, Item 3) on frame (Figure 2, Item 1) with eight lockwashers (Figure 2, Item 4) and screws (Figure 2, Item 5). Install boom roller (Figure 2, Item 11) on outer boom (Figure 2, Item 10) with six lockwashers (Figure 2, Item 12) and screws (Figure 2, Item 13).
11. 12.
0688-4
TM 9-2320-272-23-4
0688
1 2 2 3 4 5
3 5 4
10
13 12
11
M6071DAA
Boom Roller Installation.
0688-5
TM 9-2320-272-23-4
0688
FOLLOW-ON MAINTENANCE Install inner boom. (WP 0687) END OF TASK END OF WORK PACKAGE
0688-6
TM 9-2320-272-23-4
0689
FIELD MAINTENANCE CRANE SWIVEL VALVE REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Wrench, Torque, Click, Ratcheting, 1/2" Drive, 250 Ft-Lb (Volume 5, WP 0826, Table 1, Item 63) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Lockwasher (Volume 5, WP 0827, Table 1, Item 186) Qty: 6 Lockwasher (Volume 5, WP 0827, Table 1, Item 405) Qty: 1 Lockwasher (Volume 5, WP 0827, Table 1, Item 425) Qty: 1 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Boom removed. (WP 0686) Battery ground cables disconnected. (Volume 2, WP 0350)
0689-1
TM 9-2320-272-23-4
0689
REMOVAL
NOTE
Tag all parts for installation. 1. 2. 3. 4. Disconnect wires (Figure 1, Items 4 and 5) of electrical swivel harness (Figure 1, Item 3) from crane wiring harness (Figure 1, Item 6). Remove nut (Figure 1, Item 7), ground wire (Figure 1, Item 8), nut (Figure 1, Item 7), and lockwasher (Figure 1, Item 9) from frame (Figure 1, Item 10) through underside of vehicle. Discard lockwasher. Disconnect swivel wire harness (Figure 1, Item 12), wires (Figure 1, Items 13 and 16), and ground wire (Figure 1, Item 14) from floodlight harness (Figure 1, Item 15). Remove screw (Figure 1, Item 1), lockwasher (Figure 1, Item 2), and washer (Figure 1, Item 17) from electrical swivel (Figure 1, Item 11). Discard lockwasher.
0689-2
TM 9-2320-272-23-4
0689
REMOVAL - Continued
1
2 17 16 15 14 13 12 11
10 9 7 8 7 6 5 4 3
M6072DAA
Figure 1.
Wiring Harness Removal.
0689-3
TM 9-2320-272-23-4
0689
REMOVAL - Continued
WARNING
CAUTION
NOTE
Have drainage container ready to catch oil. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. Tag all hydraulic lines and fittings for installation. 5. 6. 7. 8. 9. Disconnect hydraulic lines (Figure 2, Items 7, 10, 13, and 15) from lower end of hydraulic swivel valve (Figure 2, Item 3). Remove adapter fittings (Figure 2, Items 6, 8, 9, 11, 12, 14, 16, and 17) from lower end of hydraulic swivel valve (Figure 2, Item 3). Disconnect hydraulic lines (Figure 2, Items 1 and 18) from hydraulic swivel valve (Figure 2, Item 3). Disconnect hydraulic tube (Figure 2, Item 5) from elevating cylinder tee (Figure 2, Item 4) and swivel valve (Figure 2, Item 3). Remove adapter fittings (Figure 2, Items 2 and 19) from hydraulic swivel valve (Figure 2, Item 3).
0689-4
TM 9-2320-272-23-4
0689
REMOVAL - Continued
2 3 4
18
19
15 16
17 6 7
14
8 9
13 12
11
10
M9999DAA
Figure 2.
Crane Swivel Valve Removal.
0689-5
TM 9-2320-272-23-4
0689
REMOVAL - Continued 10. 11. Remove six screws (Figure 3, Item 3) and lockwashers (Figure 3, Item 4) from hydraulic swivel valve (Figure 3, Item 6) and turntable (Figure 3, Item 5). Discard lockwashers. Install utility chain (Figure 3, Item 2) on hydraulic swivel valve (Figure 3, Item 6).
NOTE
Assistant will assist with Step (8). 12. 13. Attach hoist hook (Figure 3, Item 1) to chain (Figure 3, Item 2) and lift valve (Figure 3, Item 6) from turntable (Figure 3, Item 5). Remove utility chain (Figure 3, Item 2) and hoist hook (Figure 3, Item 1) from hydraulic swivel valve (Figure 3, Item 6).
0689-6
TM 9-2320-272-23-4
0689
REMOVAL - Continued
1 2
3 4
M6073DAA
Crane Swivel Valve Removal.
0689-7
TM 9-2320-272-23-4
0689
INSTALLATION 1. Install utility chain (Figure 4, Item 2) and hoist hook (Figure 4, Item 1) on hydraulic swivel valve (Figure 4, Item 8).
WARNING
NOTE
Assistant will help with Step (2). 2. Align valve guide pins (Figure 4, Item 5) on swivel valve (Figure 4, Item 8) with slots (Figure 4, Item 7) in turntable (Figure 4, Item 6) and install with six lockwashers (Figure 4, Item 4) and screws (Figure 4, Item 3). Tighten screws 44 to 61 lb-ft (60 to 83 Nm). Remove hoist (Figure 4, Item 1) hook and utility chain (Figure 4, Item 2) from hydraulic swivel valve (Figure 4, Item 8).
3.
0689-8
TM 9-2320-272-23-4
0689
1 2
3 4
7
M6074DAA
Figure 4.
Crane Swivel Valve Installation.
0689-9
TM 9-2320-272-23-4
0689
INSTALLATION - Continued 4. 5. 6. 7. 8. Install adapter fitting (Figure 5, Item 17) on swivel valve (Figure 5, Item 1) and adapter fitting (Figure 5, Item 19) on adapter fitting. Connect hydraulic tube (Figure 5, Item 3) to swivel valve (Figure 5, Item 1) and elevating cylinder tee (Figure 5, Item 2). Connect hydraulic lines (Figure 5, Items 16 and 18) to hydraulic swivel valve (Figure 5, Item 1). Install adapter fittings (Figure 5, Items 4, 6, 7, 9, 10, 12, 14, and 15) on lower end of hydraulic swivel valve (Figure 5, Item 1). Connect hydraulic lines (Figure 5, Items 5, 8, 11, and 13) to fittings on lower end of hydraulic swivel valve (Figure 5, Item 1).
0689-10
TM 9-2320-272-23-4
0689
18
19 1 2
16
17
13 14
15 4 5
12
6 7
11 10
8
M6074-1DAA
Crane Swivel Valve Installation.
0689-11
TM 9-2320-272-23-4
0689
WIRING HARNESS CONNECTION 1. 2. 3. 4. Install washer (Figure 6, Item 17), lockwasher (Figure 6, Item 2), and screw (Figure 6, Item 1) on electrical swivel (Figure 6, Item 11). Connect wires (Figure 6, Items 13 and 16), ground wire (Figure 6, Item 14), and swivel wire harness (Figure 6, Item 12) to floodlight harness (Figure 6, Item 15). Connect wires (Figure 6, Items 4 and 5) of swivel harness (Figure 6, Item 3) to crane wiring harness (Figure 6, Item 6) at underside of vehicle. At underside of vehicle, install lockwasher (Figure 6, Item 9), nut (Figure 6, Item 7), ground wire (Figure 6, Item 8), and nut (Figure 6, Item 7) on frame (Figure 6, Item 10).
0689-12
TM 9-2320-272-23-4
0689
WIRING HARNESS CONNECTION - Continued

1
2 17 16 15 14 13 12 11
10 9 7 8 7 6 5 4 3
M6075DAA
Wiring Harness Connections.
0689-13
TM 9-2320-272-23-4
0689
FOLLOW-ON MAINTENANCE 1. 2. Install boom and check for leaks. (WP 0686) Connect battery ground cables. (Volume 2, WP 0350)
0689-14
TM 9-2320-272-23-4
0690
FIELD MAINTENANCE CRANE HYDRAULIC SWING MOTOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Wrench, Torque, Click, Ratcheting, 1/2" Drive, 250 Ft-Lb (Volume 5, WP 0826, Table 1, Item 63) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Lockwasher (Volume 5, WP 0827, Table 1, Item 408) Qty: 4 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0690-1
TM 9-2320-272-23-4
0690
REMOVAL
CAUTION
When disconnecting hydraulic lines, plug all openings to prevent dirt from entering and causing internal damage to parts.
NOTE
Have drainage container ready to catch oil. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. Tag all hydraulic flex lines and adapter elbows for installation. 1. 2. 3. 4. Disconnect hydraulic flex lines (Figure 1, Items 1 and 2) from elbows (Figure 1, Items 3 and 4). Remove four screws (Figure 1, Item 7) and lockwashers (Figure 1, Item 6) from swing motor (Figure 1, Item 5) and gearcase (Figure 1, Item 8). Discard lockwashers. Remove swing motor (Figure 1, Item 5) from gearcase (Figure 1, Item 8). Remove elbows (Figure 1, Items 3 and 4) from swing motor (Figure 1, Item 5).
0690-2
TM 9-2320-272-23-4
0690
REMOVAL - Continued
4 8 7 6 5
M6076DAA
Figure 1. Crane Hydraulic Swing Motor Removal. END OF TASK
0690-3
TM 9-2320-272-23-4
0690
INSTALLATION 1. 2. 3. Install adapter elbows (Figure 2, Items 3 and 4) on swing motor (Figure 2, Item 5). Install swing motor (Figure 2, Item 5) on gearcase (Figure 2, Item 8) with four lockwashers (Figure 2, Item 6) and screws (Figure 2, Item 7). Tighten screws 44 to 61 lb-ft (60 to 83 Nm). Connect hydraulic flex lines (Figure 2, Items 1 and 2) to elbows (Figure 2, Items 3 and 4).
4
M6077DAA
Figure 2. Crane Hydraulic Swing Motor Installation. END OF TASK
0690-4
TM 9-2320-272-23-4
0690
FOLLOW-ON MAINTENANCE 1. 2. Fill hydraulic oil reservoir to proper oil level. (TM 9-2320-272-10) Operate swing control lever to check swing motor for proper operation. (TM 9-2320-272-10)
0690-5/6 blank
TM 9-2320-272-23-4
0691
FIELD MAINTENANCE CRANE SWING GEARCASE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Lockwasher (Volume 5, WP 0827, Table 1, Item 408) Qty: 6 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Crane hydraulic swing motor removed. (WP 0690)
0691-1
TM 9-2320-272-23-4
0691
REMOVAL 1. 2. Remove six screws (Figure 1, Item 4) and lockwashers (Figure 1, Item 3) from crane swing gearcase (Figure 1, Item 1) and turntable (Figure 1, Item 2). Discard lockwashers. Remove gearcase (Figure 1, Item 1) from turntable (Figure 1, Item 2).
1
2
4 3
M10359DAA
Figure 1. Crane Swing Gearcase Removal. END OF TASK INSTALLATION Install gearcase (Figure 2, Item 1) on turntable (Figure 2, Item 2) with six lockwashers (Figure 2, Item 3) and screws (Figure 2, Item 4).
0691-2
TM 9-2320-272-23-4
0691
1
2
4 3
M6079DAA
Crane Swing Gearcase Installation.
Install crane hydraulic swing motor. (WP 0690) END OF TASK END OF WORK PACKAGE
0691-3/4 blank
TM 9-2320-272-23-4
0692
FIELD MAINTENANCE TURNTABLE REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Chain Assembly (Volume 5, WP 0826, Table 1, Item 15) Hoist Assembly Wrench, Torque, Click, Ratcheting, 3/4" Drive, 600 Ft-Lb (Volume 5, WP 0826, Table 1, Item 61) Materials/Parts Cleaning Compound, Solvent (Volume 5, WP 0825, Table 1, Item 16, 17) Locknut (Volume 5, WP 0827, Table 1, Item 317) Qty: 18 Personnel Required (2) References TM 9-237 Volume 5, WP 0820 Equipment Condition Parking brake set. (TM 9-2320-272-10) Hydraulic oil reservoir removed. (WP 0703) Boom elevating cylinders removed. (WP 0693) Hydraulic swivel valve removed. (WP 0689) Crane swing gearcase removed. (WP 0691) Gondola removed. (WP 0699)
0692-1
TM 9-2320-272-23-4
0692
REMOVAL
WARNING
All personnel must stand clear during lifting operations. A snapped chain, or shifting or swinging load, may result in injury to personnel. Failure to comply may result in injury or death to personnel. 1. Remove 18 locknuts (Figure 1, Item 3), screws (Figure 1, Item 5), two turntable side plates (Figure 1, Item 1), and crossover tubes (Figure 1, Item 2) from turntable base plate (Figure 1, Item 4). Discard locknuts. Remove 18 screws (Figure 1, Item 8) from turntable gear and bearing (Figure 1, Item 9) and crane body (Figure 1, Item 10) by rotating turntable base plate (Figure 1, Item 4) so access hole exposes each screw.
2.
NOTE
Assistant will help with Steps (3) and (4). 3. 4. 5. Attach two utility chains (Figure 1, Item 6) to turntable base plate (Figure 1, Item 4). Attach lifting device (Figure 1, Item 7) to chains and lift turntable base plate (Figure 1, Item 4) away from crane body (Figure 1, Item 10). Remove two utility chains (Figure 1, Item 6) and lifting device (Figure 1, Item 7) from turntable base plate (Figure 1, Item 4).
1 2 6 7 3 8
10 9 5
M9698DAA
Figure 1.
Turntable Removal.
0692-2
TM 9-2320-272-23-4
0692
REMOVAL - Continued 6. Remove 18 screws (Figure 2, Item 2) and turntable gear and bearing assembly (Figure 2, Item 1) from underside of turntable base plate (Figure 2, Item 3).
M9700DAA
Turntable Gear and Bearing Removal.
0692-3
TM 9-2320-272-23-4
0692
WARNING
Solvent cleaning compound is flammable and toxic. Do not use near an open flame and always have a fire extinguisher nearby when solvents are used. Use only in well-ventilated places, wear protective clothing, and dispose of cleaning rags in approved container. Failure to comply may result in damage to equipment, injury, or death to personnel. 1. 2. 3. Clean turntable base plate and gear and bearing assembly with solvent cleaning compound. Inspect turntable base plate for cracks and breaks. If cracked or broken, refer to TM 9-237. Inspect turntable gear and bearing assembly for cracks, pits, scores, and broken teeth. If cracked, pitted, scored, or broken teeth are evident, replace turntable gear and bearing assembly.
END OF TASK INSTALLATION 1. Install turntable gear and bearing assembly (Figure 3, Item 1) on underside of turntable base plate (Figure 3, Item 3) with 18 screws (Figure 3, Item 2). Tighten screws 170 to 200 lb-ft (231 to 271 Nm).
0692-4
TM 9-2320-272-23-4
0692
M6089DAA
Figure 3.
Turntable Gear and Bearing Installation.
0692-5
TM 9-2320-272-23-4
0692
WARNING
NOTE
Assistant will help with Steps (1) and (2). 2. 3. 4. 5. Attach two utility chains (Figure 4, Item 6) to turntable base plate (Figure 4, Item 4). Attach lifting device (Figure 4, Item 7) to two utility chains (Figure 4, Item 6) and lift turntable base plate (Figure 4, Item 4) onto crane body (Figure 3, Item 10). Remove two utility chains and hoist hook from turntable base plate (Figure 4, Item 4). Rotate turntable base plate (Figure 4, Item 4) on gear bearing assembly (Figure 4, Item 9) to expose each screw hole in turntable base plate and install on crane body (Figure 4, Item 10) with 18 screws (Figure 4, Item 5). Tighten screws 170 to 200 lb-ft (231 to 271 Nm). Install turntable side plates (Figure 4, Item 1) and crossover tubes (Figure 4, Item 2) on turntable base plate (Figure 4, Item 4) with 18 screws (Figure 4, Item 5) and locknuts (Figure 4, Item 3). Tighten screws 170 to 200 lb-ft (231 to 271 Nm).
6.
0692-6
TM 9-2320-272-23-4
0692
1 2 6 7 3 8
10 9 5
M9699DAA
Turntable Installation.
0692-7
TM 9-2320-272-23-4
0692
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Install gondola. (WP 0699) Install crane swing gearcase. (WP 0691) Install hydraulic swivel valve. (WP 0689) Install boom elevating cylinders. (WP 0693) Lubricate gear bearing. (Volume 5, WP 0820) Install hydraulic oil reservoir. (WP 0703)
0692-8
TM 9-2320-272-23-4
0693
FIELD MAINTENANCE BOOM ELEVATING CYLINDER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Chain Assembly (Volume 5, WP 0826, Table 1, Item 15) Lifting Device Wrench, Torque, Click, Ratcheting, 1/2" Drive, 250 Ft-Lb (Volume 5, WP 0826, Table 1, Item 63) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Cotter Pin (Volume 5, WP 0827, Table 1, Item 351) Qty: 1 Lockwasher (Volume 5, WP 0827, Table 1, Item 405) Qty: 1 Personnel Required (2) References Volume 5, WP 0820 Equipment Condition Parking brake set. (TM 9-2320-272-10) Boom lowered. (TM 9-2320-272-10) Hydraulic oil reservoir drained. (WP 0703)
0693-1
TM 9-2320-272-23-4
0693
REMOVAL
CAUTION
When disconnecting hydraulic lines and hoses, plug all openings to prevent dirt from entering and causing internal parts damage.
NOTE
Left and right elevating cylinders are removed and installed in the same way. Right elevating cylinder is shown. Have drainage container ready to catch oil. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. Tag lines for installation. 1. Disconnect cylinder oil supply line (Figure 1, Item 6) and oil return line (Figure 1, Item 5) from cylinder adapter fitting (Figure 1, Item 11) and snubber valve (Figure 1, Item 10) at bottom of elevating cylinder (Figure 1, Item 12).
WARNING
Assistant must remain at crane controls until removal operation is completed. Injury to personnel may result if boom control lever is accidentally engaged while work is being done between raised boom and swivel base. Failure to comply may result in injury or death to personnel. All personnel must stand clear during hoisting operations. A snapped cable, or swinging or shifting load, may occur. Failure to comply may result in injury or death to personnel. 2. 3. Using chain (Figure 1, Item 13) and lifting device (Figure 1, Item 14), lift boom (Figure 1, Item 1) until boom weight is fully supported and upper retaining pin (Figure 1, Item 2) is free. Remove screw (Figure 1, Item 4), lockwasher (Figure 1, Item 3), and upper retaining pin (Figure 1, Item 2) from elevating cylinder (Figure 1, Item 12) and boom (Figure 1, Item 1). Discard lockwasher.
WARNING
Elevating cylinder is heavy. Remove with the aid of assistant and a lifting device. Failure to comply may result in injury or death to personnel. 4. 5. Remove cotter pin (Figure 1, Item 7), lower retaining pin (Figure 1, Item 8), and elevating cylinder (Figure 1, Item 12) from turntable (Figure 1, Item 9). Discard cotter pin. Using chain (Figure 1, Item 13) and lifting device (Figure 1, Item 14), raise boom (Figure 1, Item 1) and install crane shipper braces (TM 9-2320-272-10).
0693-2
TM 9-2320-272-23-4
0693
REMOVAL - Continued
14 1
13
12
11
10 5 6
8 7
M6062DAA
Boom Elevating Cylinder Removal.
0693-3
TM 9-2320-272-23-4
0693
INSTALLATION 1. 2. 3. Using utility chain (Figure 2, Item 13) and lifting device (Figure 2, Item 14), raise boom (Figure 2, Item 1) and remove shipper braces (TM 9-2320-272-10). Install elevating cylinder (Figure 2, Item 12) on turntable (Figure 2, Item 9) with lower retaining pin (Figure 2, Item 8) and cotter pin (Figure 2, Item 7). Install elevating cylinder (Figure 2, Item 12) on boom (Figure 2, Item 1) with upper retaining pin (Figure 2, Item 2), lockwasher (Figure 2, Item 3), and screw (Figure 2, Item 4). Tighten screw 44 to 61 lb-ft (60 to 83 Nm). Connect cylinder oil supply line (Figure 2, Item 6) to snubber valve (Figure 2, Item 10). Connect oil return (Figure 2, Item 5) line to cylinder adapter fitting (Figure 2, Item 11). Remove lifting device and chain from boom (Figure 2, Item 1).
4. 5. 6.
0693-4
TM 9-2320-272-23-4
0693
14 1
13
12
11
10 5 6
8 7
M6063DAA
Figure 2. Boom Elevating Cylinder Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Fill hydraulic oil reservoir to proper level. (TM 9-2320-272-10) Operate crane through full elevating range and check for leaks at oil lines and cylinder. (TM 9-2320-272-10)
0693-5/6 blank
TM 9-2320-272-23-4
0694
FIELD MAINTENANCE FRONT WINCH MOTOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Chain Assembly (Volume 5, WP 0826, Table 1, Item 15) Lifting Device Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Tape, Antiseizing (Volume 5, WP 0825, Table 1, Item 65) Gasket (Volume 5, WP 0827, Table 1, Item 48) Qty: 1 Materials/Parts (cont.) Locknut (Volume 5, WP 0827, Table 1, Item 289) Qty: 6 Lockwasher (Volume 5, WP 0827, Table 1, Item 405) Qty: 10 References Volume 5, WP 0820 Equipment Condition Parking brake set. (TM 9-2320-272-10) Hydraulic oil reservoir drained. (Volume 5, WP 0820)
0694-1
TM 9-2320-272-23-4
0694
REMOVAL 1. 2. 3. 4. Wrap chain around front of winch (Figure 1, Item 11) and install on lifting device. Remove six screws (Figure 1, Item 1), lockwashers (Figure 1, Item 2), and washers (Figure 1, Item 3) from left and right support plates (Figure 1, Item 5) and frame rails (Figure 1, Item 10). Discard lockwashers. Loosen two screws (Figure 1, Item 4) on left and right support plates (Figure 1, Item 5). Remove six locknuts (Figure 1, Item 8), screws (Figure 1, Item 6), and washers (Figure 1, Item 7) from left and right support plates (Figure 1, Item 5) and support plate brackets (Figure 1, Item 9). Discard locknuts.
2 3 4
11 7 10 9 8
M5244DAA
Figure 1. Front Winch Motor Removal.
0694-2
TM 9-2320-272-23-4
0694
REMOVAL - Continued 5. Lift and tilt front winch (Figure 2, Item 1) until winch motor (Figure 2, Item 6) clears crossmember (Figure 2, Item 2).
CAUTION
NOTE
Have drainage container ready to catch oil. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. Tag all hydraulic lines for installation. 6. Disconnect hydraulic return hose (Figure 2, Item 4) and supply hose (Figure 2, Item 5) from elbows (Figure 2, Item 3) on winch motor (Figure 2, Item 6).
1 2
3 4
6 5
M5246DAA
Figure 2.
Front Winch Motor Removal.
0694-3
TM 9-2320-272-23-4
0694
REMOVAL - Continued 7. Remove four screws (Figure 3, Item 2), lockwashers (Figure 3, Item 3), front winch motor (Figure 3, Item 4), and gasket (Figure 3, Item 1) from winch motor adapter (Figure 3, Item 5). Discard lockwashers and gasket.
1 2
3 4 5
M5248DAA
Figure 3. Front Winch Motor Removal. END OF TASK
0694-4
TM 9-2320-272-23-4
0694
INSTALLATION
NOTE
If new winch motor is being installed, transfer fittings from old winch motor. Fittings must be clean and free of defects. Wrap all male threads with antiseize tape before installation. 1. Align winch motor shaft key (Figure 4, Item 3) with keyway of winch gear shaft (Figure 4, Item 1) and install gasket (Figure 4, Item 2) and winch motor (Figure 4, Item 6) on winch motor adapter (Figure 4, Item 7) with four lockwashers (Figure 4, Item 5) and screws (Figure 4, Item 4).
1 2 3 4
5 6 7
M5249DAA
Figure 4. 2.
Front Winch Motor Installation.
Connect hydraulic return hose (Figure 5, Item 2) and supply hose (Figure 5, Item 3) to elbows (Figure 5, Item 1) on winch motor (Figure 5, Item 4).
1 2
4 3
M5247DAA
Figure 5.
0694-5
TM 9-2320-272-23-4
0694
INSTALLATION - Continued 3. 4. 5. 6. 7. Lower front of winch (Figure 6, Item 11) and align holes of left and right support plates (Figure 6, Item 5) with holes of frame rails (Figure 6, Item 10) and support plate brackets (Figure 6, Item 9). Install six washers (Figure 6, Item 3), lockwashers (Figure 6, Item 2), and screws (Figure 6, Item 1) on left and right support plates (Figure 6, Item 5) and frame rails (Figure 6, Item 10). Finger tighten screws. Install six washers (Figure 6, Item 7), screws (Figure 6, Item 6), and locknuts (Figure 6, Item 8) on left and right support plates (Figure 6, Item 5) and support plate brackets (Figure 6, Item 9). Tighten screws (Figure 6, Items 1, 4, and 6). Remove lifting device and chain from front winch (Figure 6, Item 11).
2 3 4
11 7 10
Figure 6. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Fill hydraulic oil reservoir to proper fluid level. (Volume 5, WP 0820)
8
M5245DAA
Start engine and check winch for oil leaks and proper operation. (TM 9-2320-272-10)
0694-6
TM 9-2320-272-23-4
0695
FIELD MAINTENANCE BOOM EXTENSION CYLINDER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Chain Assembly (Volume 5, WP 0826, Table 1, Item 15) Lifting Device Materials/Parts Cotter Pin (Volume 5, WP 0827, Table 1, Item 349) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10) Inner boom removed. (WP 0687)
0695-1
TM 9-2320-272-23-4
0695
REMOVAL 1. 2. Remove cotter pin (Figure 1, Item 6) from retaining pin (Figure 1, Item 7). Drive out retaining pin (Figure 1, Item 7) from inner boom (Figure 1, Item 4) and extension cylinder (Figure 1, Item 1). Discard cotter pin. Attach chains (Figure 1, Item 2) around extension cylinder (Figure 1, Item 1) and attach to lifting device (Figure 1, Item 3).
WARNING
All personnel must stand clear during lifting operations. A snapped chain, or shifting or swinging load, may result in injury to personnel. Failure to comply may result in injury or death to personnel. 3. Slowly pull extension cylinder (Figure 1, Item 1) out of inner boom (Figure 1, Item 4) until chains (Figure 1, Item 2) can be positioned. Place extension cylinder on shop horses or jack stands (Figure 1, Item 5). Remove chains (Figure 1, Item 2) and lifting device (Figure 1, Item 3) from extension cylinder (Figure 1, Item 1).
4.
0695-2
TM 9-2320-272-23-4
0695
REMOVAL - Continued
1 2
7 6
1
Figure 1. END OF TASK Boom Extension Cylinder Removal.
M6068DAA
0695-3
TM 9-2320-272-23-4
0695
INSTALLATION 1. 2. 3. 4. Attach chains (Figure 2, Item 2) around extension cylinder (Figure 2, Item 1) and attach to lifting device (Figure 2, Item 3). Lift extension cylinder (Figure 2, Item 1) to inner boom (Figure 2, Item 4) and slide into inner boom. Install extension cylinder (Figure 2, Item 1) on inner boom (Figure 2, Item 4) with retaining pin (Figure 2, Item 7) and cotter pin (Figure 2, Item 6). Remove chains (Figure 2, Item 2) from extension cylinder (Figure 2, Item 1).
0695-4
TM 9-2320-272-23-4
0695
1 2
7 6
1
Figure 2. Boom Extension Cylinder Installation. END OF TASK
M6069DAA
0695-5
TM 9-2320-272-23-4
0695
FOLLOW-ON MAINTENANCE Install inner boom. (WP 0687) END OF TASK END OF WORK PACKAGE
0695-6
TM 9-2320-272-23-4
0696
FIELD MAINTENANCE HOIST WINCH REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Caliper, Micrometer, Inside (Volume 5, WP 0826, Table 1, Item 13) Caliper Set, Micrometer Outside (Volume 5, WP 0826, Table 1, Item 11) Chain Assembly (Volume 5, WP 0826, Table 1, Item 15) Hammer, Soft Face (Volume 5, WP 0826, Table 1, Item 22) Hoist Assembly Indicator, Dial (Volume 5, WP 0826, Table 1, Item 25) Puller Kit, Mechanical (Volume 5, WP 0826, Table 1, Item 41) Materials/Parts Grease, Automotive and Artillery (Volume 5, WP 0825, Table 1, Item 28) Lubricating Oil, Gear, Multipurpose (Volume 5, WP 0825, Table 1, Item 44, 45, 46, 47) Assembled Bolt with Washer (Volume 5, WP 0827, Table 1, Item 83) Qty: 6 Gasket (Volume 5, WP 0827, Table 1, Item 12) Qty: 1 Gasket (Volume 5, WP 0827, Table 1, Item 15) Qty: 1 Gasket (Volume 5, WP 0827, Table 1, Item 19) Qty: 1 Gasket (Volume 5, WP 0827, Table 1, Item 212) Qty: 1 Gasket (Volume 5, WP 0827, Table 1, Item 231) Qty: 1 Key (Volume 5, WP 0827, Table 1, Item 235) Qty: 4 Key, Machine Materials/Parts (cont.) (Volume 5, WP 0827, Table 1, Item 305) Qty: 1 Lockwasher (Volume 5, WP 0827, Table 1, Item 215) Qty: 10 Lockwasher (Volume 5, WP 0827, Table 1, Item 405) Qty: 15 Lockwasher (Volume 5, WP 0827, Table 1, Item 437) Qty: 12 Seal (Volume 5, WP 0827, Table 1, Item 41) Qty: 2 Seal (Volume 5, WP 0827, Table 1, Item 253) Qty: 1 Shim (Volume 5, WP 0827, Table 1, Item 16) Qty: 1 Woodruff Key (Volume 5, WP 0827, Table 1, Item 417) Qty: 1 Woodruff Key, Machine (Volume 5, WP 0827, Table 1, Item 306) Qty: 1 Personnel Required (2) References Volume 5, WP 0817 Volume 5, WP 0818 Equipment Condition Hoist gear reducer and hoist gearcase oil drained. (Volume 5, WP 0820) Hoist winch cable removed. (WP 0709) Floodlight wiring harness removed. (Volume 2, WP 0329) Hoist winch motor removed. (WP 0700)
0696-1
TM 9-2320-272-23-4
0696
REMOVAL 1. Position chain around hoist winch (Figure 1, Item 6) and attach to lifting device. Take up tension in chain.
WARNING
All personnel must stand clear during lifting operations. A swinging or shifting load may occur. Failure to comply may result in injury or death to personnel. Ensure lifting capacity is greater than weight (400 lb (182 kg)) of hoist winch. Failure to comply may result in damage to equipment, injury, or death to personnel.
NOTE
Assistant will help with Steps (2) and (3). 2. 3. 4. Remove 12 screws (Figure 1, Item 5), lockwashers (Figure 1, Item 4), and hoist winch (Figure 1, Item 6) from boom (Figure 1, Item 1). Discard lockwashers. Lower hoist winch (Figure 1, Item 6) from boom (Figure 1, Item 1) and remove hoist winch from vehicle. Remove lifting device (Figure 1, Item 2) and chain (Figure 1, Item 3) from hoist winch (Figure 1, Item 6).
0696-2
TM 9-2320-272-23-4
0696
REMOVAL - Continued
3 4 5
M6056DAA
Hoist Winch Removal.
0696-3
TM 9-2320-272-23-4
0696
DISASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Remove four screws (Figure 2, Item 1) and lockwashers (Figure 2, Item 2), adapter (Figure 2, Item 23), and gasket (Figure 2, Item 3) from cover (Figure 2, Item 22). Discard lockwashers and gasket. Remove woodruff key (Figure 2, Item 5) from input shaft (Figure 2, Item 6). Discard woodruff key. Remove ten screws (Figure 2, Item 20), lockwashers (Figure 2, Item 21), cover (Figure 2, Item 22), and gasket (Figure 2, Item 7) from housing (Figure 2, Item 12). Discard lockwashers and gasket. Remove bearing (Figure 2, Item 8) from cover (Figure 2, Item 22). Remove input shaft gear (Figure 2, Item 4) and input shaft (Figure 2, Item 6) from housing (Figure 2, Item 12). Remove input shaft gear (Figure 2, Item 4) from input shaft (Figure 2, Item 6). Remove snapring (Figure 2, Item 15) from worm shaft (Figure 2, Item 19). Using puller, remove drive gear (Figure 2, Item 16) from worm shaft (Figure 2, Item 19). Remove woodruff key (Figure 2, Item 9) from worm shaft (Figure 2, Item 19). Discard woodruff key. Remove four screws (Figure 2, Item 14), lockwashers (Figure 2, Item 13), housing (Figure 2, Item 12), and gasket (Figure 2, Item 11) from gearcase (Figure 2, Item 10). Discard lockwashers and gasket. Remove bearing (Figure 2, Item 17) and seal (Figure 2, Item 18) from housing (Figure 2, Item 12). Discard seal.
0696-4
TM 9-2320-272-23-4
0696
1 2 3
23 22 4 6 8 7 5
20
21
9 10
19 18 17 16 15 11 12 14 13
M9485DAA
Figure 2.
Hoist Winch Disassembly.
0696-5
TM 9-2320-272-23-4
0696
NOTE
Record thickness of shim(s) for assembly. 12. Remove screw (Figure 3, Item 6), lockwasher (Figure 3, Item 7), washer (Figure 3, Item 5), shim(s) (Figure 3, Item 8), and bracket (Figure 3, Item 9) from drum shaft (Figure 3, Item 2). Discard shim(s) and lockwasher. Remove thrust washer (Figure 3, Item 10) and drum (Figure 3, Item 11) from drum shaft (Figure 3, Item 2). Remove two woodruff keys (Figure 3, Item 4) and thrust washer (Figure 3, Item 12) from drum shaft (Figure 3, Item 2). Discard woodruff keys. Remove screw (Figure 3, Item 13), plate (Figure 3, Item 14), and gasket (Figure 3, Item 3) from drum shaft (Figure 3, Item 2) and gearcase (Figure 3, Item 1). Discard gasket.
13. 14. 15.
0696-6
TM 9-2320-272-23-4
0696
2 14 4 3
13
12
11 10 9 8 7 6
M10267DAA
Figure 3.
0696-7
TM 9-2320-272-23-4
0696
DISASSEMBLY - Continued 16. 17. Remove six screw assembled lockwashers (Figure 4, Item 14), cover (Figure 4, Item 15), and gasket (Figure 4, Item 16) from brake housing (Figure 4, Item 13). Discard screw assembled lockwashers and gasket. Remove screw (Figure 4, Item 19), washer (Figure 4, Item 20), seal (Figure 4, Item 21), spring (Figure 4, Item 18), and brake band (Figure 4, Item 17) from brake drum (Figure 4, Item 4) and brake housing (Figure 4, Item 13). Discard seal. Remove screw (Figure 4, Item 1), lockwasher (Figure 4, Item 2), and washer (Figure 4, Item 3) from brake drum (Figure 4, Item 4) and worm shaft (Figure 4, Item 8). Using puller, remove brake drum (Figure 4, Item 4) from worm shaft (Figure 4, Item 8) and brake housing (Figure 4, Item 13). Remove woodruff key (Figure 4, Item 11) from worm shaft (Figure 4, Item 8). Discard woodruff key.
18. 19. 20.
NOTE
Mark brake housing and gearcase for assembly. 21. Remove four screws (Figure 4, Item 5) and lockwashers (Figure 4, Item 6), brake housing (Figure 4, Item 13), and gasket (Figure 4, Item 7) from gearcase (Figure 4, Item 9). Discard lockwashers and gasket. Remove seal (Figure 4, Item 12) from brake housing (Figure 4, Item 13). Discard seal.
22.
0696-8
TM 9-2320-272-23-4
0696
3 1 2
9 5 6 19 20 21 7 8
12 11 13 18 17 15 14 16
10
M6057DAA
Figure 4.
0696-9
TM 9-2320-272-23-4
0696
DISASSEMBLY - Continued 23. 24. 25. 26. 27. 28. Using soft-head hammer, tap on end of worm shaft (Figure 5, Item 16) to drive bearing (Figure 5, Item 2) from bore of gearcase (Figure 5, Item 1). Using puller, remove bearing (Figure 5, Item 2) from worm shaft (Figure 5, Item 16). Align bearing (Figure 5, Item 15) with bore of gearcase (Figure 5, Item 1). Using softhead hammer, tap opposite end of worm shaft (Figure 5, Item 16) and remove worm shaft (Figure 5, Item 16) with bearing from gearcase. Use puller or arbor press to remove bearing (Figure 5, Item 15) from worm shaft (Figure 5, Item 16). Remove screw (Figure 5, Item 11), lockwasher (Figure 5, Item 10), and washer (Figure 5, Item 9) from drum shaft (Figure 5, Item 14) and cover (Figure 5, Item 4). Discard lockwasher. Remove four screws (Figure 5, Item 6) and lockwashers (Figure 5, Item 7), screws (Figure 5, Item 5), cover (Figure 5, Item 4), and gasket (Figure 5, Item 3) from gearcase (Figure 5, Item 1). Discard lockwashers and gasket. Remove seal (Figure 5, Item 8) from cover (Figure 5, Item 4). Discard seal. Using softhead hammer, tap on drum end of drum shaft (Figure 5, Item 14) to remove drum shaft and worm gear (Figure 5, Item 12) from gearcase (Figure 5, Item 1). Using arbor press, remove worm gear (Figure 5, Item 12) from drum shaft (Figure 5, Item 14). Remove two woodruff keys (Figure 5, Item 13) from drum shaft (Figure 5, Item 14). Discard woodruff keys.
29. 30. 31. 32.
0696-10
TM 9-2320-272-23-4
0696
2 1 16
3 4 5 6
15 14 13
13
7 9 10
11 12
M6057-1DAA
0696-11
TM 9-2320-272-23-4
0696
CLEANING AND INSPECTION 1. 2. 3. For General Cleaning Instructions, refer to (Volume 5, WP 0817). For General Inspection Instructions, refer to (Volume 5, WP 0818). Inspect drum shaft, input shaft(s), and worm shafts for bends, cracks, breaks, chips, and wear. Refer to Table 1, Hoist Winch Wear Limits, for measurements. Replace drum shaft, input shaft, and worm shaft if damaged or worn. Inspect drum, cover, gearcase, bracket, and plate for cracks, bends, damaged threads, and wear. Refer to Table 1, Hoist Winch Wear Limits, for measurements. Replace drum, cover, gearcase, bracket, and plate, if damaged or worn. Inspect gearcase bearings and thrust washers for wear. Refer to Table 1, Hoist Winch Wear Limits, for measurements. Replace gearcase bearings and thrust washers if worn. Inspect worm gear and input shaft gear for cracks, nicks, burrs, ridged, chipped, broken teeth, or particles in teeth of worm gear. Refer to Table 1, Hoist Winch Wear Limits, for measurements. Replace worm gear and input shaft gear, if damaged or worn.
4.
5. 6.
0696-12
TM 9-2320-272-23-4
0696
Table 1.
Hoist Winch Wear Limits. WEAR LIMITS/TOLERANCES
ITEM NO.
ITEM/POINT OF MEASUREMENT INCHES MILLIMETERS
1, 2
Shaft support (2) Inner diameter - bushing - maximum Drum shaft Outer diameter - four places - minimum Worm shaft Outer diameter - bearing journal - minimum Outer diameter - sealing surface - minimum Input shaft - outer diameter minimum Gearcase Inner diameter - bushing - maximum Width - cover edge to hub Inner diameter - bearing bores (2) - maximum Cover Inner diameter - bushing - maximum Width - bushing hub - minimum
2.130
54.10
2.123
53.92
1.771 1.765 1.746
44.98 44.83 43.35
5 6
2.130 4.469 3.937
54.10 113.51 100.00
2.130 2.000
54.10 50.8
Bearings (2) Inner diameter - inner race - maximum Outer diameter - outer race - minimum Drum - outer diameter - minimum Thrust washers (2) - thickness - minimum Worm gear - width - hub - minimum Input shaft gear
1.771 3.936 4.992 0.062 2.492 1.88
44.98 99.97 126.80 1.57 63.30 47.75
9 10 11 12 END OF TASK
0696-13
TM 9-2320-272-23-4
0696
ASSEMBLY
NOTE
Coat all internal hoist winch parts with lubrication oil before installation. Coat inside lips of seals with GAA grease before installation. 1. 2. 3. 4. 5. 6. 7. Install two woodruff keys (Figure 6, Item 13) on drum shaft (Figure 6, Item 14). Using arbor press, install drum shaft (Figure 6, Item 14) in worm gear (Figure 6, Item 12) until drum shaft extends 2.50 in. (63.5 mm) from face of hub. Insert drum shaft (Figure 6, Item 14) through gearcase (Figure 6, Item 1) until hub is seated. Using arbor press, install bearing (Figure 6, Item 15) on worm shaft (Figure 6, Item 16). Ensure bearing seats on shoulder of worm shaft. Insert worm shaft (Figure 6, Item 16) into gearcase (Figure 6, Item 1). Using arbor press, install bearing (Figure 6, Item 2) into bore of gearcase (Figure 6, Item 1) until seated on shoulder of worm shaft (Figure 6, Item 16), flush with face of gearcase. Install dial indicator on gearcase (Figure 6, Item 1), and measure backlash of worm gear (Figure 6, Item 12) and worm shaft (Figure 6, Item 16). Backlash should be 0.006 to 0.010 in. (0.15 to 0.25 mm). Replace worm gear if backlash is not within limits. Using arbor press, install seal (Figure 6, Item 8) in cover (Figure 6, Item 4). Install gasket (Figure 6, Item 3) and cover (Figure 6, Item 4) on gearcase (Figure 6, Item 1) with four screws (Figure 6, Item 5), lockwashers (Figure 6, Item 7), and screws (Figure 6, Item 6). Install washer (Figure 6, Item 9) and lockwasher (Figure 6, Item 11) on cover (Figure 6, Item 4) and drum shaft (Figure 6, Item 14) with screw (Figure 6, Item 10). Install dial indicator on gearcase (Figure 6, Item 1). Check end play of drum shaft (Figure 6, Item 14). a. b. c. End play should be 0.005 to 0.015 in. (0.13 to 0.38 mm). If end play is less than 0.005 in. (0.13 mm), remove cover (Figure 6, Item 4) and remove gasket(s) (Figure 6, Item 3). Recheck end play. If end play is more than 0.015 in. (0.38 mm), remove cover (Figure 6, Item 4) and add gasket(s) (Figure 6, Item 3). Install cover (Figure 6, Item 4) on drum shaft (Figure 6, Item 14) and recheck end play.
8. 9. 10. 11. 12.
0696-14
TM 9-2320-272-23-4
0696
2 1 16
3 4 5 6
15 14 13
13
7 9
11 12
10
M6059DAA
Figure 6.
Hoist Winch Assembly.
0696-15
TM 9-2320-272-23-4
0696
ASSEMBLY - Continued 13. 14. 15. 16. 17. Install seal (Figure 7, Item 5) in brake housing (Figure 7, Item 6). Install gasket (Figure 7, Item 17) and brake housing (Figure 7, Item 6) on gearcase (Figure 7, Item 2) with four lockwashers (Figure 7, Item 16) and screws (Figure 7, Item 15). Install woodruff key (Figure 7, Item 4) on worm shaft (Figure 7, Item 1). Install brake drum (Figure 7, Item 21) on worm shaft (Figure 7, Item 1) with washer (Figure 7, Item 20), lockwashers (Figure 7, Item 19), and screw (Figure 7, Item 18). Install brake band (Figure 7, Item 10) and spring (Figure 7, Item 11) on brake housing (Figure 7, Item 6) and brake drum (Figure 7, Item 21) with seal (Figure 7, Item 14), washer (Figure 7, Item 13), and screw (Figure 7, Item 12). Install gasket (Figure 7, Item 7) and cover (Figure 7, Item 8) on brake housing (Figure 7, Item 6) with six screw assembled lockwashers (Figure 7, Item 9). Install gasket (Figure 7, Item 22) and plate (Figure 7, Item 33) on gearcase (Figure 7, Item 2) and drum shaft (Figure 7, Item 3) with screw (Figure 7, Item 32). Install two woodruff keys (Figure 7, Item 23) on drum shaft (Figure 7, Item 3). Install thrust washer (Figure 7, Item 31) and drum (Figure 7, Item 30) on drum shaft (Figure 7, Item 3). Tap with soft-head hammer to seat drum (Figure 7, Item 30) against thrust washer (Figure 7, Item 31) on plate (Figure 7, Item 33).
18. 19. 20. 21.
NOTE
Ensure shims are installed to prerecorded thickness. 22. Install thrust washer (Figure 7, Item 29), bracket (Figure 7, Item 28), and shim(s) (Figure 7, Item 27) on drum shaft (Figure 7, Item 30) with washer (Figure 7, Item 24), lockwashers (Figure 7, Item 26), and screw (Figure 7, Item 25).
0696-16
TM 9-2320-272-23-4
0696
21 20 18 19 2 15 16 12 13 14 17 1 33 23 2
3 22
32 5 6
3 31
11 10 8 9
7 30 29 28 27 26 25 24
M6059-1DAA
Figure 7.
0696-17
TM 9-2320-272-23-4
0696
ASSEMBLY - Continued 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. Install seal (Figure 8, Item 18) and bearing (Figure 8, Item 17) on housing (Figure 8, Item 12). Install gasket (Figure 8, Item 11) and housing (Figure 8, Item 12) on gearcase (Figure 8, Item 10) with four lockwashers (Figure 8, Item 13) and screws (Figure 8, Item 14). Install woodruff key (Figure 8, Item 9) in worm shaft (Figure 8, Item 19). Using puller, install drive gear (Figure 8, Item 16) on worm shaft (Figure 8, Item 19). Install snapring (Figure 8, Item 15) on worm shaft (Figure 8, Item 19). Install input shaft gear (Figure 8, Item 4) on input shaft (Figure 8, Item 6). Install input shaft (Figure 8, Item 6) and input shaft gear (Figure 8, Item 4) on housing (Figure 8, Item 12). Install bearing (Figure 8, Item 8) on cover (Figure 8, Item 20). Install gasket (Figure 8, Item 7) and cover (Figure 8, Item 20) on housing (Figure 8, Item 12) with ten lockwashers (Figure 8, Item 22) and screws (Figure 8, Item 21). Install woodruff key (Figure 8, Item 5) in input shaft (Figure 8, Item 6). Install gasket (Figure 8, Item 3) and adapter (Figure 8, Item 23) on cover (Figure 8, Item 20) with four lockwashers (Figure 8, Item 2) and screws (Figure 8, Item 1).
0696-18
TM 9-2320-272-23-4
0696
1 2 3
23
21
22 6 8 5
9 10
20
19 18 17 15 16 11 12 14 13
M6060DAA
0696-19
TM 9-2320-272-23-4
0696
INSTALLATION 1. Install chain (Figure 9, Item 3) on hoist winch (Figure 9, Item 6) and attach to lifting device (Figure 9, Item 2).
WARNING
All personnel must stand clear during lifting operations. A swinging or shifting load may occur. Failure to comply may result in injury or death to personnel. Ensure lifting capacity is greater than weight of hoist winch (400 lb) (182 kg). Failure to comply may result in damage to equipment, injury, or death to personnel.
NOTE
Assistant will help with Steps (2) and (3). 2. 3. Raise hoist winch (Figure 9, Item 6) and position on boom (Figure 9, Item 1). Install hoist winch (Figure 9, Item 6) on boom (Figure 9, Item 1) with 12 lockwashers (Figure 9, Item 4) and screws (Figure 9, Item 5).
3 4 5
M6061DAA
Figure 9. Hoist Winch Installation. END OF TASK
0696-20
TM 9-2320-272-23-4
0696
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Install hoist level wind. (WP 0697) Install hoist winch motor. (WP 0700) Install floodlight wiring harness. (TM 9-2320-260-20) Fill gear reducer and hoist winch gearcase with gear oil. (Volume 5, WP 0820) Start engine and check hoist winch operation. (TM 9-2320-260-10) Install hoist winch cable. (WP 0709)
0696-21/22 blank
TM 9-2320-272-23-4
0697
FIELD MAINTENANCE HOIST LEVEL WIND REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin Materials/Parts (cont.) (Volume 5, WP 0827, Table 1, Item 345) Qty: 1 Locknut (Volume 5, WP 0827, Table 1, Item 324) Qty: 8 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0697-1
TM 9-2320-272-23-4
0697
REMOVAL
NOTE
Front and rear roller braces are replaced the same way. 1. 2. 3. 4. 5. 6. Remove four locknuts (Figure 1, Item 9), screws (Figure 1, Item 2), and two front roller braces (Figure 1, Item 4) from boom (Figure 1, Item 1). Discard locknuts. Remove two cotter pins (Figure 1, Item 3) from shaft (Figure 1, Item 7). Discard cotter pins. Remove shaft (Figure 1, Item 7) and level wind roller (Figure 1, Item 6) from two roller braces (Figure 1, Item 4). Remove shaft (Figure 1, Item 7) from roller (Figure 1, Item 6). Remove two bearings (Figure 1, Item 5) from roller (Figure 1, Item 6). Remove grease fitting (Figure 1, Item 8) from shaft (Figure 1, Item 7).
3 4 8 7 9 3 4 5 6
M6054DAA
Figure 1. Hoist Level Wind Removal. END OF TASK
0697-2
TM 9-2320-272-23-4
0697
INSTALLATION 1. 2. 3. 4. 5. Install two bearings (Figure 2, Item 5) in roller (Figure 2, Item 6). Install grease fitting (Figure 2, Item 8) in shaft (Figure 2, Item 7). Install shaft (Figure 2, Item 7) in roller (Figure 2, Item 6). Install two braces (Figure 2, Item 4) on shaft (Figure 2, Item 7) with two cotter pins (Figure 2, Item 3). Install two roller braces (Figure 2, Item 4) on boom (Figure 2, Item 1) with four screws (Figure 2, Item 2) and locknuts (Figure 2, Item 9).
3 4 8 7 9 3 4 5 6
M6055DAA
Hoist Level Wind Installation.
0697-3/4 blank
TM 9-2320-272-23-4
0698
FIELD MAINTENANCE CRANE GONDOLA CONTROL VALVE REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Remover, Seal Retainer (Volume 5, WP 0826, Table 1, Item 49) Vise, Machinist's (Volume 5, WP 0826, Table 1, Item 59) Wrench, Torque, Click, Ratcheting, 1/2" Drive, 250 Ft-Lb (Volume 5, WP 0826, Table 1, Item 63) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Cleaning Compound, Solvent (Volume 5, WP 0825, Table 1, Item 16, 17) Cloth, Cleaning (Volume 5, WP 0825, Table 1, Item 19) Load Check Valve Kit (Volume 5, WP 0827, Table 1, Item 181) Qty: 4 Locknut (Volume 5, WP 0827, Table 1, Item 324) Qty: 4 Lockwasher (Volume 5, WP 0827, Table 1, Item 405) Qty: 4 Materials/Parts (cont.) O-ring (Volume 5, WP 0827, Table 1, Item 358) Qty: 1 O-ring (Volume 5, WP 0827, Table 1, Item 365) Qty: 4 O-ring (Volume 5, WP 0827, Table 1, Item 366) Qty: 1 Parts Kit, Winch (Volume 5, WP 0827, Table 1, Item 182) Snapring (Volume 5, WP 0827, Table 1, Item 433) Qty: 8 References Volume 5, WP 0820 Equipment Condition Parking brake set. (TM 9-2320-272-10) Hydraulic oil reservoir drained. (TM 9-2320-272-10)
0698-1
TM 9-2320-272-23-4
0698
REMOVE 1. Remove five screws (Figure 1, Item 1) and control valve cover (Figure 1, Item 2) from gondola (Figure 1, Item 3).
1 2
M9672DAA
Figure 1.
Control Valve Cover Removal.
0698-2
TM 9-2320-272-23-4
0698
REMOVE - Continued
CAUTION
When disconnecting hydraulic lines, plug all openings to prevent dirt from entering and causing internal damage to parts.
NOTE
Have drainage container ready to catch oil. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. Tag hydraulic lines for installation. 2. 3. 4. 5. Disconnect hydraulic oil reservoir crossover tube (Figure 2, Item 6) from control valve elbow (Figure 2, Item 7). Remove control valve elbow (Figure 2, Item 7) from control valve adapter (Figure 2, Item 8). Disconnect hydraulic elevating cylinder crossover tube (Figure 2, Item 5) from control valve adapter fitting (Figure 2, Item 1). Remove control valve tube (Figure 2, Item 3) from hydraulic swivel valve flex line (Figure 2, Item 4) and hydraulic control valve adapter (Figure 2, Item 2).
2 3
4
M9673DAA
Figure 2.
Hose Removal.
0698-3
TM 9-2320-272-23-4
0698
REMOVE - Continued 6. 7. 8. 9. Disconnect two hydraulic swing motor flex lines (Figure 3, Item 5) from control valve adapter fittings (Figure 3, Item 4). Disconnect two hydraulic crowd cylinder flex lines (Figure 3, Item 6) from control valve adapter fittings (Figure 3, Item 3). Disconnect two hydraulic hoist motor flex lines (Figure 3, Item 7) from control valve adapter fittings (Figure 3, Item 2). Remove four locknuts (Figure 3, Item 8), screws (Figure 3, Item 10), and control valve (Figure 3, Item 1) from gondola (Figure 3, Item 9). Discard locknuts.
9 10 1 2 3 4
7 6 5
M9675DAA
Figure 3. Crane Gondola Control Valve Disassembly. END OF TASK
0698-4
TM 9-2320-272-23-4
0698
DISASSEMBLY
WARNING
Solvent cleaning compound is flammable and toxic. Do not use near an open flame and always have a fire extinguisher nearby when solvents are used. Use only in well-ventilated places, wear protective clothing, and dispose of cleaning rags in approved container. Failure to comply may result in damage to equipment, injury, or death to personnel. 1. 2. Thoroughly clean exterior of crane control valve (Figure 4, Item 3) with solvent cleaning compound (Volume 5, WP 0817). Remove eight snaprings (Figure 4, Item 5), pins (Figure 4, Item 2), and four handles (Figure 4, Item 1) from base (Figure 4, Item 4) and crane control valve (Figure 4, Item 3). Discard snaprings.
2 3
M9678DAA
Figure 4. Crane Gondola Control Valve Disassembly.
0698-5
TM 9-2320-272-23-4
0698
DISASSEMBLY - Continued 3. Remove four nuts (Figure 5, Item 13), lockwashers (Figure 5, Item 14), screws (Figure 5, Item 1), brackets (Figure 5, Items 7 and 15), and base (Figure 5, Item 2) from crane control valve (Figure 3, Item 3). Discard lockwashers. Remove nipple adapter (Figure 5, Item 17) and o-ring (Figure5, Item 16) from crane control valve (Figure 5, Item 3). Discard o-ring. Remove nipple (Figure 5, Item 18) from nipple adapter (Figure 5, Item 17).
4. 5.
NOTE
Mark position and angle of tube and all elbows for assembly. 6. 7. 8. Remove tube (Figure 5, Item 6), connector (Figure 5, Item 5), and o-ring (Figure 5, Item 4) from crane control valve (Figure 5, Item 3). Discard o-ring. Remove two elbows (Figure 5, Item 10), three adapters (Figure 5, Item 11), and two o-rings (Figure 5, Item 12) from crane control valve (Figure 5, Item 3). Discard o-rings. Remove four elbows (Figure 5, Item 9) and o-rings (Figure 5, Item 8) from crane control valve (Figure 5, Item 3). Discard o-rings.
1 2
3 18 17 16 15 4 5 6 8 14 13 11 11 9 10
12
7
M9677DAA
0698-6
TM 9-2320-272-23-4
0698
NOTE
All spring-centered spool valves in the control valve are removed and disassembled the same way. Three spool valves are stamped with a D (double action) on the shank of the spool valve. The fourth is stamped with an S (single action) and is located next to the oil outlet port in the control valve. Steps (9) through (12) will cover a double-action valve only. 9. 10. 11. Remove spool valve cap (Figure 6, Item 2) and spool valve (Figure 6, Item 1) from crane control valve (Figure 6, Item 8). Clamp spool valve (Figure 6, Item 1) in soft-jawed vise. Using improvised compression tool, compress spring (Figure 6, Item 5) and remove snapring (Figure 6, Item 3), outer spacer (Figure 6, Item 4), spring, travel limit washer (Figure 6, Item 6), and inner spacer (Figure 6, Item 7) from spool valve (Figure 6, Item 1).
1
8 2 3 4 5 6 7
M9679DAA
0698-7
TM 9-2320-272-23-4
0698
DISASSEMBLY - Continued 12. Using seal retainer remover and replacer (Figure 7, Item 22), remove retainer (Figure 7, Item 19), seal (Figure 7, Item 20), and o-ring (Figure 7, Item 21) from crane control valve (Figure 7, Item 3). Discard seal and o-ring. Remove two check valve caps (Figure 7, Item 8), springs (Figure 7, Item 11), and poppets (Figure 7, Item 12) from crane control valve (Figure 7, Item 3). Remove backup ring (Figure 7, Item 10), o-ring (Figure 7, Item 9), backup ring (Figure 7, Items 1 and 4), backup ring (Figure 7, Item 5), o-ring (Figure 7, Item 6), and o-ring (Figure 7, Item 7) from each check valve cap (Figure 7, Item 8). Discard backup rings and o-rings. Remove relief valve (Figure 7, Item 18) from crane control valve (Figure 7, Item 3). Discard relief valve. Remove seat retainer plug (Figure 7, Item 13), drain sleeve (Figure 7, Item 5), and seat retainer (Figure 7, Item 15) from crane control valve (Figure 7, Item 3). Discard seat retainer. Remove poppet spring (Figure 7, Item 17) and poppet assembly (Figure 7, Item 16) from crane control valve (Figure 7, Item 3). Discard poppet assembly and poppet spring.
13. 14.
15. 16. 17.
0698-8
TM 9-2320-272-23-4
0698
1 7 8 6 5 2 3 4 5 6
8 7
9 10 11 12 11 9 10 14 15 13
21 20 19 16 17 18 3 22
Figure 7. END OF TASK Crane Control Valve Disassembly.
M9680DAA
0698-9
TM 9-2320-272-23-4
0698
WARNING
Solvent cleaning compound is flammable and toxic. Do not use near an open flame and always have a fire extinguisher nearby when solvents are used. Use only in well-ventilated places, wear protective clothing, and dispose of cleaning rags in approved container. Failure to comply may result in damage to equipment, injury, or death to personnel. 1. 2. Clean all control valve components with solvent cleaning compound and dry with lint-free cloth (Volume 5, WP 0817). Inspect spool valve and crane control valve. Replace crane control valve if grooved, scratched, cracked, or broken.
NOTE
Drain sleeve should go into control valve far enough to leave to or three full threads exposed. Installing seat retainer plug at this point sets the seat retainer to the proper depth. 1. 2. 3. 4. 5. 6. Install seat retainer (Figure 8, Item 12) and drain sleeve (Figure 8, Item 13) in crane control valve (Figure 8, Item 1). Install seat retainer plug (Figure 8, Item 11) in crane control valve (Figure 8, Item 1). Install poppet assembly (Figure 8, Item 16) and poppet spring (Figure 8, Item 15) in crane control valve (Figure 8, Item 1) so poppet assembly points toward seat retainer (Figure 8, Item 12). Install relief valve (Figure 8, Item 14) on crane control valve (Figure 8, Item 1). Install o-rings (Figure 8, Items 4 and 5), backup rings (Figure 8, Items 2 and 3), o-ring (Figure 8, Item 7), and backup ring (Figure 8, Item 8) on each check valve cap (Figure 8, Item 6). Install two poppets (Figure 8, Item 10), springs (Figure 8, Item 9), and check valve caps (Figure 8, Item 6) into crane control valve (Figure 8, Item 1).
0698-10
TM 9-2320-272-23-4
0698
5 6
2 2 1 3 4
6 5
10
7 8 9 10 9 8 7 13 12 11
M9932DAA
16 15 14
Figure 8. Crane Gondola Control Valve Assembly.
0698-11
TM 9-2320-272-23-4
0698
NOTE
The remaining check valve caps are assembled the same way. 7. 8. Clamp spool valve (Figure 9, Item 1) in soft-jawed vise. Using improvised compression tool, compress spring (Figure 9, Item 5) and install inner spacer (Figure 9, Item 7), travel limit washer (Figure 9, Item 6), spring, and outer spacer (Figure 9, Item 4) on spool valve (Figure 9, Item 1) with snapring (Figure 9, Item 3). Install spool valve (Figure 9, Item 1) and spool valve cap (Figure 9, Item 2) in crane control valve (Figure 9, Item 11). Using seal retainer remover and replacer (Figure 9, Item 12), install o-ring (Figure 9, Item 10), seal (Figure 9, Item 9), and retainer (Figure 9, Item 8) on crane control valve (Figure 9, Item 11).
9. 10.
1 11
1 10 9 8 5 6 1 7 4 3
3 12
M6084DAA
0698-12
TM 9-2320-272-23-4
0698
NOTE
Install all parts in Steps (11) through (13) in their marked location and angle on control valve. The three remaining spool valves are assembled into the control valve in the same way. 11. Install four o-rings (Figure 10, Item 8), elbows (Figure 10, Item 9), two o-rings (Figure 10, Item 12), three adapters (Figure 10, Item 11), two elbows (Figure 10, Item 10), o-ring (Figure 10, Item 4), connector (Figure 10, Item 5), and tube (Figure 10, Item 6) on crane control valve. Install nipple adapter (Figure 10, Item 17) on nipple (Figure 10, Item 18). Install o-ring (Figure 10, Item 16) and nipple adapter (Figure 10, Item 17) on crane control valve (Figure 10, Item 3). Install right control bracket (Figure 10, Item 7), left control bracket (Figure 10, Item 15), and base (Figure 10, Item 2) on crane control valve (Figure 10, Item 3) with four screws (Figure 10, Item 1), lockwashers (Figure 10, Item 4), and nuts (Figure 10, Item 13).
12. 13. 14.
1 2
3 18 17 16 15 4 5 6 8 14 13 11 11 9 10
12
7
M9676DAA
0698-13
TM 9-2320-272-23-4
0698
ASSEMBLY - Continued 15. Align four operating handles (Figure 11, Item 1) with holes in base (Figure 11, Item 4) and control spool valves (Figure 11, Item 3), and install four operating handles with eight pins (Figure 11, Item 2) and snaprings (Figure 11, Item 5).
2 3
M6081DAA
Crane Gondola Control Valve Assembly.
0698-14
TM 9-2320-272-23-4
0698
INSTALLATION
NOTE
If new crane control valve is being installed, fittings from old crane control valve may be used. Two side control plates and base may be used. Fittings must be cleaned and inspected for cracks and stripped threads. During installation, make sure all hydraulic lines are connected at their marked locations. 1. 2. 3. 4. Install control valve (Figure 12, Item 1) on gondola (Figure 12, Item 9) with four screws (Figure 12, Item 10) and locknuts (Figure 12, Item 8). Tighten screws 44 to 61 lb-ft (60 to 83 Nm). Install two hydraulic hoist motor flex lines (Figure 12, Item 7) on control valve adapter fittings (Figure 12, Item 2). Install two hydraulic crowd cylinder flex lines (Figure 12, Item 6) on control valve adapter fittings (Figure 12, Item 3). Install two hydraulic swing motor flex lines (Figure 12, Item 5) on control valve adapter fittings (Figure 12, Item 4).
9 10 1 2 3 4
7 6 5
M9928DAA
Figure 12. Crane Gondola Control Valve Installation.
0698-15
TM 9-2320-272-23-4
0698
INSTALLATION - Continued 5. 6. 7. 8. Install control valve tube (Figure 13, Item 3) on hydraulic swivel valve flex line (Figure 13, Item 4) and hydraulic control valve adapter (Figure 13, Item 2). Install hydraulic elevating cylinder crossover tube (Figure 13, Item 5) on control valve adapter (Figure 13, Item 1). Install control valve elbow (Figure 13, Item 7) on hydraulic control valve adapter (Figure 13, Item 8). Install hydraulic oil reservoir crossover tube (Figure 13, Item 6) on control valve elbow (Figure 13, Item 7).
2 3
4
M9674DAA
Figure 13. Crane Gondola Control Valve Installation.
0698-16
TM 9-2320-272-23-4
0698
INSTALLATION - Continued 9. Install control valve cover (Figure 14, Item 2) on gondola (Figure 14, Item 3) with five screws (Figure 14, Item 1).
1 2
M6080DAA
Figure 14. Crane Gondola Control Valve Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Fill hydraulic oil reservoir to proper oil level. (Volume 5, WP 0820) Check pressure relief valve adjustment. (WP 0705)
0698-17/18 blank
TM 9-2320-272-23-4
0699
FIELD MAINTENANCE GONDOLA REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Chain Assembly (Volume 5, WP 0826, Table 1, Item 15) Hoist Assembly Wrench, Torque, Click, Ratcheting, 1/2" Drive, 250 Ft-Lb (Volume 5, WP 0826, Table 1, Item 63) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 285) Qty: 3 Locknut (Volume 5, WP 0827, Table 1, Item 324) Qty: 12 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Crane control valve removed. (WP 0698) Floodlight assembly removed. (Volume 2, WP 0329)
0699-1
TM 9-2320-272-23-4
0699
REMOVAL
WARNING
All personnel must stand clear during lifting operations. A snapped chain, or shifting or swinging load, may result in injury to personnel. Failure to comply may result in injury or death to personnel. 1. Remove hydraulic tube (Figure 1, Item 2) from elevating cylinder crossover tee (Figure 1, Item 8) and control valve flex line (Figure 1, Item 3).
NOTE
Tag all lines for installation. 2. 3. Remove three locknuts (Figure 1, Item 6), clamps (Figure 1, Item 5), and six hydraulic flex lines (Figure 1, Item 7) from gondola (Figure 1, Item 1). Discard locknuts. Remove hydraulic swivel valve flex line (Figure 1, Item 4) from gondola (Figure 1, Item 1).
0699-2
TM 9-2320-272-23-4
0699
REMOVAL - Continued
3 2 8 4 5 6
7 7 5 14 13 9
10
11
12
M6087DAA
Figure 1.
Gondola Removal.
0699-3
TM 9-2320-272-23-4
0699
REMOVAL - Continued 4. 5. 6. Remove gondola guard (Figure 2, Item 9) from gondola (Figure 2, Item 1). Attach two utility chains (Figure 2, Item 13) to gondola (Figure 2, Item 1). Attach hoist hook (Figure 2, Item 14) to utility chains and remove slack.
CAUTION
Ensure all hydraulic lines and wires are fastened clear of gondola to avoid snagging during removal.
NOTE
Assistant will help with Step (7). 7. Remove 12 locknuts (Figure 2, Item 11) and screws (Figure 2, Item 12) from turntable side plate (Figure 2, Item 10) and lift gondola (Figure 2, Item 1) away from side plate (Figure 2, Item 10). Discard locknuts. Remove lifting device (Figure 2, Item 14) and two utility chains (Figure 2, Item 13) from gondola (Figure 2, Item 1).
8.
1 7 6 5
4
M6088DAA
Gondola Removal.
0699-4
TM 9-2320-272-23-4
0699
INSTALLATION 1. 2. Attach two utility chains to gondola (Figure 3, Item 5). Attach lifting device to two utility chains.
NOTE
Assistant will help with Step (3). When positioning gondola, guide all hydraulic lines through opening. 3. 4. 5. Lift gondola (Figure 3, Item 5) to turntable side plate (Figure 3, Item 2) and install with 12 screws (Figure 3, Item 4) and locknuts (Figure 3, Item 3). Tighten screws 44 to 61 lb-ft (60 to 83 Nm). Remove two utility chains and hoist hook from gondola (Figure 3, Item 5). Install gondola guard (Figure 3, Item 1) on gondola (Figure 3, Item 5).
1 7 6 5
4
M6088DAA
Figure 3.
Gondola Installation.
0699-5
TM 9-2320-272-23-4
0699
INSTALLATION - Continued 6. 7. 8. Guide hydraulic swivel valve flex line (Figure 4, Item 4) through hole in gondola (Figure 4, Item 1). Install six hydraulic flex lines (Figure 4, Item 7) on gondola (Figure 4, Item 1) with three clamps (Figure 4, Item 5) and locknuts (Figure 4, Item 6). Install hydraulic tube (Figure 4, Item 2) on elevating cylinder crossover tee (Figure 4, Item 9) and control valve flex line (Figure 4, Item 3).
2 3
2 4 5
5
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install crane control valve. (WP 0698) Install floodlight assembly. (Volume 2, WP 0329) Gondola Installation.
M9785DAA
0699-6
TM 9-2320-272-23-4
0700
FIELD MAINTENANCE HYDRAULIC HOIST WINCH MOTOR AND LINES REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Wrench, Torque, Click, Ratcheting, 1/2" Drive, 250 Ft-Lb (Volume 5, WP 0826, Table 1, Item 63) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Gasket (Volume 5, WP 0827, Table 1, Item 14) Qty: 1 Locknut (Volume 5, WP 0827, Table 1, Item 275) Qty: 4 Lockwasher Materials/Parts (cont.) (Volume 5, WP 0827, Table 1, Item 408) Qty: 4 Woodruff Key (Volume 5, WP 0827, Table 1, Item 417) Qty: 1 References Volume 5, WP 0820 Equipment Condition Parking brake set. (TM 9-2320-272-10) Hydraulic oil reservoir drained. (WP 0703)
0700-1
TM 9-2320-272-23-4
0700
REMOVAL
CAUTION
NOTE
Have drainage container ready to catch oil. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. Tag lines and hoses for installation. 1. 2. 3. 4. Disconnect two steel hydraulic lines (Figure 1, Item 4) from elbows (Figure 1, Item 9). Disconnect two hydraulic flex hoses (Figure 1, Item 5) from steel hydraulic lines (Figure 1, Item 4). Remove four locknuts (Figure 1, Item 3), washers (Figure 1, Item 2), clamps (Figure 1, Item 1), and two steel hydraulic lines (Figure 1, Item 4) from boom (Figure 1, Item 12). Discard locknuts. Remove four screws (Figure 1, Item 7), lockwashers (Figure 1, Item 6), hoist motor (Figure 1, Item 10), and gasket (Figure 1, Item 11) from winch gearbox adapter (Figure 1, Item 8). Discard lockwashers and gasket. Clean gasket remains from mating surface. Remove woodruff key (Figure 1, Item 13) from gear shaft (Figure 1, Item 14).
5.
0700-2
TM 9-2320-272-23-4
0700
REMOVAL - Continued
12 9 10 11
8 7 6 5
13
10
14
M6052DAA
Figure 1. Hydraulic Hoist Winch Motor and Lines Removal. END OF TASK
0700-3
TM 9-2320-272-23-4
0700
INSTALLATION 1. 2. Install woodruff key (Figure 2, Item 13) in slot of gear shaft (Figure 2, Item 14) on hoist motor (Figure 2, Item 10). Install hoist motor (Figure 2, Item 10) on winch gearbox adapter (Figure 2, Item 8) with gasket (Figure 2, Item 11), four lockwashers (Figure 2, Item 6) and screws (Figure 2, Item 7). Tighten screws 60 to 70 lb-ft (81 to 95 Nm). Install two steel hydraulic lines (Figure 2, Item 4) on boom (Figure 2, Item 12) with four clamps (Figure 2, Item 1), washers (Figure 2, Item 2), and locknuts (Figure 2, Item 3). Connect two steel hydraulic lines (Figure 2, Item 4) to elbows (Figure 2, Item 9). Connect two hydraulic flex hoses (Figure 2, Item 5) to steel hydraulic lines (Figure 2, Item 4).
3. 4. 5.
12 9 10 11
8 7 6 5
13
10
14
M6053DAA
Figure 2. Hydraulic Hoist Winch Motor and Lines Installation. END OF TASK
0700-4
TM 9-2320-272-23-4
0700
FOLLOW-ON MAINTENANCE 1. 2. Fill hydraulic oil reservoir to proper level. (Volume 5, WP 0820) Check hoist motor for proper operation. (TM 9-2320-272-10)
0700-5/6 blank
TM 9-2320-272-23-4
0701
FIELD MAINTENANCE WINCH HYDRAULIC OIL RESERVOIR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Tape, Antiseizing (Volume 5, WP 0825, Table 1, Item 65) Materials/Parts (cont.) Locknut (Volume 5, WP 0827, Table 1, Item 285) Qty: 8 Tiedown Strap (Volume 5, WP 0827, Table 1, Item 328) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10) Hydraulic oil reservoir drained. (Volume 5, WP 0820)
0701-1
TM 9-2320-272-23-4
0701
REMOVAL
WARNING
Accidental or intentional introduction of liquid contaminants into the environment is in violation of state, federal, and military regulations. Refer to local Unit SOP for information concerning storage, use, and disposal of these liquids. Failure to comply may result in injury or death to personnel.
CAUTION
NOTE
Have drainage container ready to catch oil. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. Tag all hydraulic lines for installation. 1. 2. 3. Remove tiedown straps from oil supply hose (Figure 1, Item 6) as required. Discard tiedown straps. While holding nut (Figure 1, Item 5), loosen nut (Figure 1, Item 4) and remove oil supply hose (Figure 1, Item 6) from elbow (Figure 1, Item 1). Remove elbow (Figure 1, Item 1) and nipple (Figure 1, Item 2) from reservoir (Figure 1, Item 3).
0701-2
TM 9-2320-272-23-4
0701
REMOVAL - Continued
1 2
4 5
6
M5272DAA
Figure 1. Winch Hydraulic Oil Reservoir Removal.
0701-3
TM 9-2320-272-23-4
0701
REMOVAL - Continued 4. 5. 6. 7. 8. 9. 10. Loosen nut (Figure 2, Item 4) and remove oil return hose (Figure 2, Item 3) from elbow (Figure 2, Item 5). Remove nut (Figure 2, Item 13), screw (Figure 2, Item 2), clamp (Figure 2, Item 1), and oil return hose (Figure 2, Item 3) from reservoir (Figure 2, Item 10). Remove eight locknuts (Figure 2, Item 12) and screws (Figure 2, Item 11) from frame bracket (Figure 2, Item 14) and reservoir (Figure 2, Item 10). Discard locknuts. Remove and pull reservoir (Figure 2, Item 10) out about 2 in. (5 cm) from frame bracket (Figure 2, Item 14). Remove reservoir (Figure 2, Item 10) from frame bracket (Figure 2, Item 14). Remove elbow (Figure 2, Item 5) from reservoir (Figure 2, Item 10). Remove filler cap (Figure 2, Item 9), dipstick (Figure 2, Item 8), spacer (Figure 2, Item 7), and strainer (Figure 2, Item 6) from reservoir (Figure 2, Item 10).
9 8 7 1 2 3 4 5 6
14 10 13
11
12 11 12
M5274DAA
Figure 2. Winch Hydraulic Oil Reservoir Removal. END OF TASK
0701-4
TM 9-2320-272-23-4
0701
INSTALLATION
NOTE
When new hydraulic oil reservoir is installed, use attaching parts and fittings from old hydraulic oil reservoir. Wrap all male pipe threads with antiseize tape before installation. 1. 2. 3. 4. 5. 6. Install strainer (Figure 3, Item 6), spacer (Figure 3, Item 7), dipstick (Figure 3, Item 8), and filler cap (Figure 3, Item 9) on reservoir (Figure 3, Item 10). Install elbow (Figure 3, Item 5) on reservoir (Figure 3, Item 10). Position reservoir (Figure 3, Item 10) on frame bracket (Figure 3, Item 14). Install reservoir (Figure 3, Item 10) on frame bracket (Figure 3, Item 14) with eight screws (Figure 3, Item 11) and locknuts (Figure 3, Item 12). Install oil return hose (Figure 3, Item 3) on elbow (Figure 3, Item 5) and tighten nut (Figure 3, Item 4). Install oil return hose (Figure 3, Item 3) on reservoir (Figure 3, Item 10) with clamp (Figure 3, Item 1), screw (Figure 3, Item 2), and nut (Figure 3, Item 13).
9 8 7 1 2 3 4 5 6
14 10 13
11
12 11 12
M5275DAA
Figure 3. Winch Hydraulic Oil Reservoir Installation.
0701-5
TM 9-2320-272-23-4
0701
INSTALLATION - Continued 7. 8. 9. Install nipple (Figure 4, Item 2) and elbow (Figure 4, Item 1) on reservoir (Figure 4, Item 3). Install oil supply hose (Figure 4, Item 6) on elbow (Figure 4, Item 1), and while holding nut (Figure 4, Item 5), tighten nut (Figure 4, Item 4). Install tiedown straps on oil supply hose (Figure 4, Item 6) as required.
1 2
4 5
6
M5273DAA
Figure 4. Winch Hydraulic Oil Reservoir Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Fill hydraulic oil reservoir to proper fluid level. (Volume 5, WP 0820) Operate hydraulic system and check for leaks. (TM 9-2320-2720-10)
0701-6
TM 9-2320-272-23-4
0702
FIELD MAINTENANCE TRACTOR WINCH HYDRAULIC OIL RESERVOIR REPLACEMENT (M932/A1/A2)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Tape, Antiseizing (Volume 5, WP 0825, Table 1, Item 65) Locknut (Volume 5, WP 0827, Table 1, Item 271) Qty: 2 Locknut (Volume 5, WP 0827, Table 1, Item 287) Qty: 4 Locknut (Volume 5, WP 0827, Table 1, Item 289) Qty: 6 Locknut (Volume 5, WP 0827, Table 1, Item 319) Qty: 1 Materials/Parts (cont.) Lockwasher (Volume 5, WP 0827, Table 1, Item 186) Qty: 4 O-ring (Volume 5, WP 0827, Table 1, Item 360) Qty: 1 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Spare tire removed. (TM 9-2320-272-10) Hydraulic oil reservoir drained. (Volume 5, WP 0820)
0702-1
TM 9-2320-272-23-4
0702
REMOVAL
WARNING
Accidental or intentional introduction of liquid contaminants into the environment is in violation of state, federal, and military regulations. Refer to local Unit SOP for information concerning storage, use, and disposal of these liquids. Failure to comply may result in injury or death to personnel.
CAUTION
NOTE
Have drainage container ready to catch oil. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. Tag all hydraulic lines for installation. 1. Remove two locknuts (Figure 1, Item 4), screws (Figure 1, Item 2), and brace (Figure 1, Item 5) from muffler support (Figure 1, Item 1) and reservoir base (Figure 1, Item 3). Discard locknuts.
0702-2
TM 9-2320-272-23-4
0702
REMOVAL - Continued
4 2
5 4
2
M5276DAA
Figure 1. Tractor Winch Hydraulic Oil Reservoir Removal.
0702-3
TM 9-2320-272-23-4
0702
REMOVAL - Continued 2. 3. While holding nut (Figure 2, Item 15), disconnect oil supply line (Figure 2, Item 14) from elbow (Figure 2, Item 8). Remove four screws (Figure 2, Item 13), lockwashers (Figure 2, Item 12), two split flanges (Figure 2, Item 11), oil supply hose (Figure 2, Item 14), and o-ring (Figure 2, Item 10) from hydraulic oil pump (Figure 2, Item 9). Discard lockwashers and o-ring. Remove two locknuts (Figure 2, Item 4), washers (Figure 2, Item 3), and U-bolt (Figure 2, Item 18) from nipple support (Figure 2, Item 2). Discard locknuts. Remove elbow (Figure 2, Item 8) and nipple (Figure 2, Item 7) from reservoir (Figure 2, Item 1). Remove two locknuts (Figure 2, Item 16), screws (Figure 2, Item 5), washers (Figure 2, Item 6), and nipple support (Figure 2, Item 2) from reservoir base (Figure 2, Item 17). Discard locknuts.
4. 5. 6.
0702-4
TM 9-2320-272-23-4
0702
REMOVAL - Continued
1 2 3 4
5 6 18 7 8
9 17 16 15 11 12 11 13 14
M5279DAA
10
Figure 2. Tractor Winch Hydraulic Oil Reservoir Removal.
0702-5
TM 9-2320-272-23-4
0702
REMOVAL - Continued 7. 8. 9. 10. While holding nut (Figure 3, Item 16), disconnect oil return line (Figure 3, Item 6) from elbow (Figure 3, Item 15). Remove locknut (Figure 3, Item 19), screw (Figure 3, Item 17), clamp (Figure 3, Item 18), and oil return hose (Figure 3, Item 6) from reservoir base (Figure 3, Item 5). Discard locknut. Remove four locknuts (Figure 3, Item 3), screws (Figure 3, Item 4), and muffler support (Figure 3, Item 2) from reservoir base (Figure 3, Item 5). Discard locknuts. Remove two locknuts (Figure 3, Item 8), washers (Figure 3, Item 9), screws (Figure 3, Item 10), washers (Figure 3, Item 9), and reservoir (Figure 3, Item 1) from reservoir base (Figure 3, Item 5) and frame bracket (Figure 3, Item 7). Discard locknuts. Remove elbow (Figure 3, Item 15) from reservoir (Figure 3, Item 1). Remove filler cap (Figure 3, Item 11), dipstick (Figure 3, Item 12), spacer (Figure 3, Item 13), and strainer (Figure 3, Item 14) from reservoir (Figure 3, Item 1).
11. 12.
0702-6
TM 9-2320-272-23-4
0702
REMOVAL - Continued
12 13 11 14 1
15
16 6 2
10 5 9 7 8 6
4 17
18 6 19
M5281DAA
Figure 3. Tractor Winch Hydraulic Oil Reservoir Removal. END OF TASK
0702-7
TM 9-2320-272-23-4
0702
INSTALLATION
NOTE
When hydraulic oil reservoir is installed, use attaching parts and fittings from old hydraulic oil reservoir. Wrap all male threads with antiseize tape before installation. 1. 2. 3. 4. 5. 6. 7. Install strainer (Figure 4, Item 14), spacer (Figure 4, Item 13), dipstick (Figure 4, Item 12), and filler cap (Figure 4, Item 11) on reservoir (Figure 4, Item 1). Install elbow (Figure 4, Item 15) on reservoir (Figure 4, Item 1). Position reservoir (Figure 4, Item 1) on reservoir base (Figure 4, Item 5) and frame bracket (Figure 4, Item 7). Install reservoir (Figure 4, Item 1) on frame bracket (Figure 4, Item 7) with two washers (Figure 4, Item 9), screws (Figure 4, Item 10), washers (Figure 4, Item 9), and locknuts (Figure 4, Item 8). Install muffler support (Figure 4, Item 2) on reservoir base (Figure 4, Item 5) with four screws (Figure 4, Item 4) and locknuts (Figure 4, Item 3). Install oil return hose (Figure 4, Item 6) on elbow (Figure 4, Item 15), holding nut (Figure 4, Item 16) to prevent turning. Install oil return hose (Figure 4, Item 6) on reservoir base (Figure 4, Item 5) with clamp (Figure 4, Item 18), screw (Figure 4, Item 17), and locknut (Figure 4, Item 19).
0702-8
TM 9-2320-272-23-4
0702
12 13 11 14 1
15
16 6 2
10 5 9 7 8 6
4 17
18 6 19
M5282DAA
Figure 4.
Tractor Winch Hydraulic Oil Reservoir Installation.
0702-9
TM 9-2320-272-23-4
0702
INSTALLATION - Continued 8. 9. 10. 11. Install nipple support (Figure 5, Item 2) on reservoir base (Figure 5, Item 17) with two washers (Figure 5, Item 6), screws (Figure 5, Item 5), and locknuts (Figure 5, Item 16). Install nipple (Figure 5, Item 7) and elbow (Figure 5, Item 8) on reservoir (Figure 5, Item 1). Install U-bolt (Figure 5, Item 18) on nipple support (Figure 5, Item 2) with two washers (Figure 5, Item 3) and locknuts (Figure 5, Item 4). Install o-ring (Figure 5, Item 10) and oil supply hose (Figure 5, Item 14) on hydraulic oil pump (Figure 5, Item 9) with two split flanges (Figure 5, Item 11), four lockwashers (Figure 5, Item 12), and screws (Figure 5, Item 13). Install oil supply hose (Figure 5, Item 14) on elbow (Figure 5, Item 8), holding nut (Figure 5, Item 15) to prevent turning.
1 2 3 4
12.
5 6 18 7 8
9 17 16 15 11 12 11 13 14
M5280DAA
10
Figure 5.
0702-10
TM 9-2320-272-23-4
0702
INSTALLATION - Continued 13. Install brace (Figure 6, Item 5) on muffler support (Figure 6, Item 1) and reservoir base (Figure 6, Item 3) with two screws (Figure 6, Item 2) and locknuts (Figure 6, Item 4).
4 2
5 4
2
M5277DAA
Figure 6. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3.
Install spare tire. (TM 9-2320-272-10) Fill hydraulic oil reservoir to proper fluid level. (Volume 5, WP 0820) Operate hydraulic system and check for leaks. (TM 9-2320-272-10)
0702-11/12 blank
TM 9-2320-272-23-4
0703
FIELD MAINTENANCE WRECKER HYDRAULIC OIL RESERVOIR, BRACKETS AND STRAPS REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Qty: 3 Cleaning Compound, Solvent (Volume 5, WP 0825, Table 1, Item 16, 17) Sealing Compound (Volume 5, WP 0825, Table 1, Item 56) Tape, Antiseizing (Volume 5, WP 0825, Table 1, Item 65) Materials/Parts (cont.) Locknut (Volume 5, WP 0827, Table 1, Item 285) Qty: 6 Lockwasher (Volume 5, WP 0827, Table 1, Item 405) Qty: 8 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Floodlight assembly removed. (Volume 2, WP 0329) Fuel can bracket removed. (WP 0667) Hydraulic filter housing removed. (WP 0707) Hydraulic oil reservoir drained. (Volume 5, WP 0820)
0703-1
TM 9-2320-272-23-4
0703
REMOVAL
CAUTION
When disconnecting hydraulic lines and hoses, plug all openings to prevent dirt from entering and causing damage to parts.
NOTE
Have drainage container ready to catch oil. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. 1. 2. Disconnect hydraulic oil return hose (Figure 1, Item 6) from adapter elbow (Figure 1, Item 7). Remove two locknuts (Figure 1, Item 1) and screws (Figure 1, Item 2) from two oil reservoir retaining straps (Figure 1, Item 4). Discard locknuts and separate straps from hydraulic oil reservoir (Figure 1, Item 3).
NOTE
Assistant will help with Step (3). 3. Remove hydraulic oil reservoir (Figure 1, Item 3) from two oil reservoir brackets (Figure 1, Item 5).
0703-2
TM 9-2320-272-23-4
0703
REMOVAL - Continued
6 3
5
Figure 1. Hydraulic Oil Reservoir Removal.
M9752DAA
0703-3
TM 9-2320-272-23-4
0703
REMOVAL - Continued
NOTE
Both hydraulic oil reservoir brackets are replaced the same way. 4. 5. 6. Remove two locknuts (Figure 2, Item 2), screws (Figure 2, Item 9), straps (Figure 2, Items 3 and 4), and insulator strips (Figure 2, Item 5) from reservoir bracket (Figure 2, Item 1). Discard locknuts. Remove two insulator strips (Figure 2, Item 6) from bracket (Figure 2, Item 1). Remove four screws (Figure 2, Item 7), lockwashers (Figure 2, Item 8), and bracket (Figure 2, Item 1) from vehicle. Discard lockwashers.
1 2 3 9
8 7
5
M6050DAA
Hydraulic Oil Reservoir Brackets and Straps Removal.
0703-4
TM 9-2320-272-23-4
0703
DISASSEMBLY 1. 2. 3. Remove oil gauge (Figure 3, Item 1) and filter screen (Figure 3, Item 2) from top of oil reservoir (Figure 3, Item 3). Remove adapter elbow (Figure 3, Item 8), drain valve (Figure 3, Item 5), and pipe plugs (Figure 3, Items 4 and 7) from oil reservoir (Figure 3, Item 3). Remove pipe plug (Figure 3, Item 6) from drain valve (Figure 3, Item 5).
1
2 8 3
6 5 4
M6048DAA
Hydraulic Oil Reservoir Disassembly.
0703-5
TM 9-2320-272-23-4
0703
WARNING
Solvent cleaning compound is flammable and toxic. Do not use near an open flame and always have a fire extinguisher nearby when solvents are used. Use only in well-ventilated places, wear protective clothing, and dispose of cleaning rags in approved container. Failure to comply may result in damage to equipment, injury, or death to personnel. 1. 2. 3. Steam clean exterior of reservoir. Flush interior of reservoir with solvent cleaning compound. Inspect reservoir for leaks: a. b. c. d. e. Plug all openings in reservoir except for oil gauge and filter screen opening. Insert air hose in filter inlet and cover opening around air hose. Coat exterior of reservoir with soapy water. Apply 6 psi (41 kPa) air pressure for a minimum of two minutes and check for air bubbles indicating leaks. Repair defective reservoir if any leaks are found (TM 9-237). Replace reservoir if leaks cannot be repaired.
END OF TASK
0703-6
TM 9-2320-272-23-4
0703
ASSEMBLY 1. 2. 3. 4. 5. Install two pipe plugs (Figure 4, Items 4 and 7) on reservoir (Figure 4, Item 3). Install adapter elbow (Figure 4, Item 8) on reservoir (Figure 4, Item 3). Install drain valve (Figure 4, Item 5) on reservoir (Figure 4, Item 3). Install pipe plug (Figure 4, Item 6) in drain valve (Figure 4, Item 5). Install filter screen (Figure 4, Item 2) and oil gauge (Figure 4, Item 1) in reservoir (Figure 4, Item 3).
NOTE
If installing a new hydraulic oil reservoir, perform Step (6). Wrap all male pipe threads with antiseize tape before installation. 6. Install drain valve (Figure 4, Item 5) with pipe plug (Figure 4, Item 6), two pipe plugs (Figure 4, Items 4 and 7), adapter elbow (Figure 4, Item 8), reservoir oil filter (Figure 4, Item 2), and oil gauge (Figure 4, Item 1) on hydraulic oil reservoir (Figure 4, Item 3).
1
2 8
4 5
M9754DAA
Hydraulic Oil Reservoir, Brackets and Straps Assembly.
0703-7
TM 9-2320-272-23-4
0703
INSTALLATION 1. 2. 3. Install bracket (Figure 5, Item 1) on vehicle with four lockwashers (Figure 5, Item 8) and screws (Figure 5, Item 7). Install two insulator strips (Figure 5, Item 6) on bracket (Figure 5, Item 1). Install two straps (Figure 5, Item 3 and 4) on bracket (Figure 5, Item 1) with two locknuts (Figure 5, Item 2) and screws (Figure 5, Item 9).
NOTE
Use adhesive sealant to install old or new insulator strips to brackets and/or straps. 4. Install two insulator strips (Figure 5, Item 5) under straps (Figure 5, Items 3 and 4).
1 2 3 9
8 7
5
M6051DAA
Figure 5. Hydraulic Oil Reservoir Brackets and Straps Installation.
0703-8
TM 9-2320-272-23-4
0703
NOTE
Assistant will help with Step (5). 5. 6. 7. Position hydraulic oil reservoir (Figure 6, Item 3) on two reservoir brackets (Figure 6, Item 5). Position two retaining straps (Figure 6, Item 4) around hydraulic oil reservoir (Figure 6, Item 3) and install with two screws (Figure 6, Item 2) and locknuts (Figure 6, Item 1). Connect hydraulic oil return hose (Figure 6, Item 6) to adapter elbow (Figure 6, Item 7).
6 3
M9753DAA
5
Figure 6. END OF TASK Hydraulic Oil Reservoir Installation.
0703-9
TM 9-2320-272-23-4
0703
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install hydraulic oil filter housing. (WP 0707) Install fuel can bracket. (WP 0667) Install floodlight assembly. (Volume 2, WP 0329) Fill hydraulic oil reservoir. (Volume 5, WP 0820) Start engine. (TM 9-2320-272-10)
0703-10
TM 9-2320-272-23-4
0704
FIELD MAINTENANCE WINCH HYDRAULIC OIL RESERVOIR FILTER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Wrench, Torque, Click, Ratcheting, 3/8" Drive, 75 Ft-Lb (Volume 5, WP 0826, Table 1, Item 62) Materials/Parts Oil Filter Element (Volume 5, WP 0827, Table 1, Item 439) Qty: 1 References Volume 5, WP 0820 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0704-1
TM 9-2320-272-23-4
0704
REMOVAL
NOTE
The oil filter is located on the right frame rail above the wet tank air reservoir. Have drainage container ready to catch oil. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. 1. 2. Loosen center bolt (Figure 1, Item 6) and remove filter housing (Figure 1, Item 7), spring (Figure 1, Item 3), and gasket (Figure 1, Item 2) from filter base (Figure 1, Item 1). Discard gasket. Remove center bolt (Figure 1, Item 6), washer (Figure 1, Item 5), and oil filter (Figure 1, Item 4) from filter housing (Figure 1, Item 7). Discard oil filter.
0704-2
TM 9-2320-272-23-4
0704
REMOVAL - Continued
6 7
M5270DAA
Figure 1. Winch Hydraulic Oil Reservoir Filter Removal. END OF TASK
0704-3
TM 9-2320-272-23-4
0704
INSTALLATION 1. 2. 3. Install washer (Figure 2, Item 5), center bolt (Figure 2, Item 6), oil filter (Figure 2, Item 4), and spring (Figure 2, Item 3) in filter housing (Figure 2, Item 7). Position gasket (Figure 2, Item 2) on filter base (Figure 2, Item 1). Install filter housing (Figure 2, Item 7) on gasket (Figure 2, Item 2) and filter base (Figure 2, Item 1) with center bolt (Figure 2, Item 6). Tighten center bolt 30 to 35 lb-ft (41 to 47 Nm).
0704-4
TM 9-2320-272-23-4
0704
6 7
M5271DAA
Figure 2. Winch Hydraulic Oil Reservoir Filter Installation. END OF TASK
0704-5
TM 9-2320-272-23-4
0704
FOLLOW-ON MAINTENANCE 1. 2. Fill hydraulic oil reservoir to proper fluid level. (Volume 5, WP 0820) Operate hydraulic system and check for leaks. (TM 9-2320-272-10)
0704-6
TM 9-2320-272-23-4
0705
FIELD MAINTENANCE PRESSURE RELIEF VALVE ADJUSTMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Pressure Checking K (Volume 5, WP 0826, Table 1, Item 40) Equipment Condition Parking brake set. (TM 9-2320-272-10) Boom secured in travel position. (TM 9-2320-272-10)
0705-1
TM 9-2320-272-23-4
0705
TESTING 1. 2. 3. 4. 5. 6. 7. 8. Remove five screws (Figure 1, Item 1) and cover (Figure 1, Item 2) from gondola (Figure 1, Item 6). Remove valve plug (Figure 1, Item 3) from valve bank (Figure 1, Item 5) and install hydraulic pressure gauge (Figure 1, Item 4). Start engine and engage crane hydraulic system (TM 9-2320-272-10). Raise engine idle to 1,250 rpm and observe hydraulic pressure gauge reading. Hydraulic pressure gauge should read 1,350 psi 25 psi (9,308 kPa 172 kPa). If reading is within limits, go to Step (7). If reading is not within limits, perform Adjustment. Remove hydraulic pressure gauge (Figure 1, Item 4) from valve bank (Figure 1, Item 5) and install plug (Figure 1, Item 3). Install cover (Figure 1, Item 2) on gondola (Figure 1, Item 6) with five screws (Figure 1, Item 1).
1 2
3 4
M10008DAA
Pressure Relief Valve Testing.
0705-2
TM 9-2320-272-23-4
0705
ADJUSTMENT 1. 2. 3. 4. 5. Remove acorn nut (Figure 2, Item 5) from valve bank (Figure 2, Item 2). While holding adjusting screw (Figure 2, Item 4), loosen jamnut (Figure 2, Item 3). Turn adjusting screw (Figure 2, Item 4) until hydraulic pressure gauge (Figure 2, Item 1) reads 1,350 psi 25 psi (9,308 kPa 172 kPa). While holding adjusting screw (Figure 2, Item 4), tighten jamnut (Figure 2, Item 3). If correct pressure cannot be achieved, notify maintenance.
3
M10009DAA
Pressure Relief Valve Adjustment.
0705-3/4 blank
TM 9-2320-272-23-4
0706
FIELD MAINTENANCE SNUBBER VALVE ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) References Volume 5, WP 0820 Equipment Condition Boom in down position. (TM 9-2320-272-10) Equipment Condition (cont.) Shipper braces in travel position. (TM 9-2320-272-10) Hydraulic tank reservoir drained. (Volume 5, WP 0820)
0706-1
TM 9-2320-272-23-4
0706
REMOVAL
WARNING
Replace snubber valve and lift cylinder adapter cap as an assembly. Do not disconnect adapter cap from snubber valve. Valve and cap are locked against spring tension. Failure to comply may result in injury or death to personnel.
CAUTION
When disconnecting hydraulic hoses and lines, plug all openings to prevent dirt from entering and causing internal parts damage.
NOTE
Tag all lines for installation. Have drainage container ready to catch oil. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. 1. 2. Disconnect hose (Figure 1, Item 1) from snubber valve (Figure 1, Item 2). Remove snubber valve (Figure 1, Item 2) from lift cylinder fitting (Figure 1, Item 3) and install plug (Figure 1, Item 4) to prevent excessive oil loss.
0706-2
TM 9-2320-272-23-4
0706
REMOVAL - Continued
3 1
4
M10006DAA
Snubber Valve Assembly Removal.
0706-3
TM 9-2320-272-23-4
0706
INSTALLATION
CAUTION
Ensure no particles of plugging become trapped in crane hydraulic system during installation of hosing or tubes. Failure to comply may result in damage to equipment. Ensure plug is removed from lift cylinder fitting before installation.
NOTE
Do not twist hose or attempt to install hose with one wrench. Hose fitting ends connected by a single hexagonal nut cannot be installed until the hexagonal nut end is connected at the opposite end. The entire hose must be free to turn whenever installing hose connected by a single hexagonal nut. 1. 2. Remove plug (Figure 2, Item 4) from lift cylinder fitting (Figure 2, Item 3) and install snubber valve (Figure 2, Item 2). Connect hose (Figure 2, Item 1) to snubber valve (Figure 2, Item 2).
0706-4
TM 9-2320-272-23-4
0706
3 1
4
M10007DAA
Snubber Valve Assembly Installation.
Fill hydraulic oil reservoir to proper fluid level. (Volume 5, WP 0820) END OF TASK END OF WORK PACKAGE
0706-5/6 blank
TM 9-2320-272-23-4
0707
FIELD MAINTENANCE CRANE HYDRAULIC FILTER AND HOUSING REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Qty: 1 Cleaning Compound, Solvent (Volume 5, WP 0825, Table 1, Item 16, 17) Tape, Antiseizing (Volume 5, WP 0825, Table 1, Item 65) O-ring (Volume 5, WP 0827, Table 1, Item 262) Qty: 1 O-ring (Volume 5, WP 0827, Table 1, Item 435) Qty: 1 Packing, Preformed Materials/Parts (cont.) (Volume 5, WP 0827, Table 1, Item 436) Qty: 1 Ring Seal (Volume 5, WP 0827, Table 1, Item 242) Qty: 1 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Hydraulic oil reservoir drained. (Volume 5, WP 0820) Fuel can bracket removed. (WP 0667)
0707-1
TM 9-2320-272-23-4
0707
REMOVAL
WARNING
Hydraulic filter assembly is under great pressure and oil will spurt out from housing during removal. Wear eyeshields during removal of assembly. Failure to comply may result in injury or death to personnel.
CAUTION
After disconnecting hydraulic lines and hoses, plug all openings to prevent dirt from entering and causing internal parts damage.
NOTE
Have drainage container ready to catch oil. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. 1. 2. 3. 4. Disconnect flex hose (Figure 1, Item 5) from hydraulic oil filter elbow (Figure 1, Item 4). Remove hydraulic oil filter elbow (Figure 1, Item 4) from filter housing (Figure 1, Item 3). Remove four screws (Figure 1, Item 7) and washers (Figure 1, Item 6) from filter housing (Figure 1, Item 3) and mounting flange (Figure 1, Item 1). Remove filter housing (Figure 1, Item 3) and o-ring (Figure 1, Item 2) from mounting flange (Figure 1, Item 1). Discard o-ring and clean o-ring remains from mating surfaces.
0707-2
TM 9-2320-272-23-4
0707
REMOVAL - Continued
5 7
M9826DAA
Figure 1.
Hydraulic Oil Filter Housing.
0707-3
TM 9-2320-272-23-4
0707
REMOVAL - Continued
NOTE
Perform Steps (4) and (5) if filter cover needs to be removed. 5. 6. 7. While holding filter cover (Figure 2, Item 2) in place, direct assistant to remove four screws (Figure 2, Item 1) from filter cover. Pull filter cover (Figure 2, Item 2) with filter assembly (Figure 2, Item 4) quickly from housing (Figure 2, Item 3). Remove o-ring (Figure 2, Item 5) from rear of filter housing (Figure 2, Item 3). Discard o-ring.
1 2
4
M9821DAA
Hydraulic Crane Filter.
0707-4
TM 9-2320-272-23-4
0707
DISASSEMBLY
NOTE
Perform Steps (1) through (5) if filter cover assembly needs to be repaired. 1. 2. 3. 4. 5. Place filter cover (Figure 3, Item 7) with filter assembly (Figure 3, Item 9) on flat surface. Pull filter assembly (Figure 3, Item 9) straight up to separate from filter cover (Figure 3, Item 7). Remove preformed packing (Figure 3, Item 8) from filter cover (Figure 3, Item 7). Discard preformed packing. Remove three screws (Figure 3, Item 1), rear cap (Figure 3, Item 2), front cap (Figure 3, Item 5), and ring seal (Figure 3, Item 6) from filter element (Figure 3, Item 9). Remove filter element (Figure 3, Item 3) from shroud (Figure 3, Item 4).
1
9 3
8 4
M9822DAA
Hydraulic Crane Filter.
0707-5
TM 9-2320-272-23-4
0707
WARNING
Solvent cleaning compound is flammable and toxic. Do not use near an open flame and always have a fire extinguisher nearby when solvents are used. Use only in wellventilated places, wear protective clothing, and dispose of cleaning rags in approved container. Failure to comply may result in damage to equipment, injury, or death to personnel. Eyeshields must be worn when cleaning with compressed air. Compressed air source will not exceed 30 psi (207 kPa). Failure to comply may result in injury or death to personnel. 1. 2. Using solvent cleaning compound, clean filter cover, rear cap, front cap, filter element, and shroud and dry with compressed air. Inspect filter cover, rear cap, front cap, filter element, and shroud for cracks, holes, and excessive wear. Replaced damaged or worn parts.
NOTE
Perform Steps (1) through (6) if filter cover assembly was disassembled. 1. 2. 3. 4. 5. 6. Install filter element (Figure 4, Item 12) over shroud (Figure 4, Item 10). Position ring seal (Figure 4, Item 7) on front cap (Figure 4, Item 9) and install front cap on filter element (Figure 4, Item 12). Position rear cap (Figure 4, Item 11) on opposite end of filter element (Figure 4, Item 12), align holes (Figure 4, Items 1 and 6), and install with three screws (Figure 4, Item 13). Install preformed packing (Figure 4, Item 3). Place filter cover (Figure 4, Item 6) on flat surface. Align key (Figure 4, Item 5) of filter cover (Figure 4, Item 6) with slot (Figure 4, Item 4) of filter assembly (Figure 4, Item 2) and install filter assembly on filter cover.
0707-6
TM 9-2320-272-23-4
0707
13 1 11 2 12 4 3 10 5 6 9 8
M9824DAA
Crane Hydraulic Filter.
0707-7
TM 9-2320-272-23-4
0707
INSTALLATION 1. Install o-ring (Figure 5, Item 5) sideways in filter housing (Figure 5, Item 4). Rotate and seat into position when o-ring contacts rear of filter housing.
WARNING
Hydraulic filter assembly is under great pressure and oil will spurt out from housing during installation. Wear eyeshields during installation of assembly. Failure to comply may result in injury or death to personnel.
CAUTION
Indicator must be level and on right side of housing during installation. Assembly will not seat if indicator is improperly positioned. Do not reuse hydraulic oil from drainage container. Damage to equipment may result if drain oil is used.
NOTE
Mechanic must seat filter assembly quickly and hold in place while assistant installs screws. Have drainage container ready to catch oil. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. 2. 3. Position filter cover (Figure 5, Item 1) with filter assembly (Figure 5, Item 2) just inside filter housing (Figure 5, Item 4). Push filter cover (Figure 5, Item 1) quickly into filter housing (Figure 5, Item 4) and install with four screws (Figure 5, Item 3).
4 5
1 4 4
M9825DAA
Figure 5.
Crane Hydraulic Filter.
0707-8
TM 9-2320-272-23-4
0707
INSTALLATION - Continued 4. 5. 6. Install o-ring (Figure 6, Item 2) and filter housing (Figure 6, Item 3) on mounting flange (Figure 6, Item 1) with four washers (Figure 6, Item 6) and screws (Figure 6, Item 7). Wrap hydraulic oil filter elbow (Figure 6, Item 4) with antiseize tape and install on hydraulic oil filter housing (Figure 6, Item 3). Connect flex hose (Figure 6, Item 5) on hydraulic oil filter elbow (Figure 6, Item 4).
5 7
M9827DAA
Figure 6. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install fuel can bracket. (WP 0667)
Hydraulic Oil Filter Housing.
Fill hydraulic oil reservoir to proper level. (Volume 5, WP 0820) Check hydraulic oil filter for proper operation. (Volume 5, WP 0822)
0707-9/10 blank
TM 9-2320-272-23-4
0708
FIELD MAINTENANCE AUTOMATIC BRAKE (HOIST WINCH) SERVICING
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Grease, Automotive and Artillery (Volume 5, WP 0825, Table 1, Item 28) Gasket (Volume 5, WP 0827, Table 1, Item 14) Qty: 1 Lockwasher (Volume 5, WP 0827, Table 1, Item 408) Qty: 6 References Volume 5, WP 0822 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0708-1
TM 9-2320-272-23-4
0708
ADJUSTMENT 1. Remove six screws (Figure 1, Item 4), lockwashers (Figure 1, Item 3), automatic brake cover (Figure 1, Item 5), and gasket (Figure 1, Item 6) from brake case (Figure 1, Item 1). Discard lockwashers and gasket. Measure distance between two ears (Figure 1, Item 7) of brake band (Figure 1, Item 8). Distance should be 1-7/32 in. 1/32 in. (31 mm 1 mm). Turn adjusting screw (Figure 1, Item 6) clockwise to tighten and counterclockwise to loosen until proper distance between band ears (Figure 1, Item 7) is reached. Position gasket (Figure 1, Item 2) on brake case (Figure 1, Item 1). Apply a light coat of grease on brake case to hold gasket in place. Position cover (Figure 1, Item 5) over gasket (Figure 1, Item 2) and brake case (Figure 1, Item 1) and install with six lockwashers (Figure 1, Item 3) and screws (Figure 1, Item 4).
2. 3. 4. 5.
3 2
6 8
7
Figure 1. Automatic Brake (Hoist Winch) Adjustment.
M9820DAA
END OF TASK
0708-2
TM 9-2320-272-23-4
0708
FOLLOW-ON MAINTENANCE Lift a heavy load with crane and check adjustment by observing slippage when trying to sustain load. If crane does not hold load, notify below depot maintenance. (Volume 5, WP 0822) END OF TASK END OF WORK PACKAGE
0708-3/4 blank
TM 9-2320-272-23-4
0709
FIELD MAINTENANCE HOIST WINCH CABLE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 186) Qty: 2 Lockwasher (Volume 5, WP 0827, Table 1, Item 316) Qty: 4 Personnel Required (2) References TB 9-352 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0709-1
TM 9-2320-272-23-4
0709
REMOVAL 1. 2. Remove four screws (Figure 1, Item 12), lockwashers (Figure 1, Item 13), washers (Figure 1, Item 14), and rear cable guard (Figure 1, Item 2) from boom (Figure 1, Item 1). Discard lockwashers. Remove two locknuts (Figure 1, Item 4), screws (Figure 1, Item 6), and spacers (Figure 1, Item 3) from inner boom (Figure 1, Item 5). Discard locknuts.
WARNING
Wear hand protection when handling winch cable. Do not handle cable with bare hands. Broken wires may be sharp. Failure to comply may result in injury or death to personnel.
NOTE
Maintain manual tension on hoist cable when removing block from cable clevis. 3. 4. 5. Unwind hoist cable (Figure 1, Item 7) (TM 9-2320-272-10) until snatch block (Figure 1, Item 8) touches ground. Place hoist control in NEUTRAL position. Remove nut (Figure 1, Item 9), anchor bolt (Figure 1, Item 10), and cable clevis (Figure 1, Item 11) from snatch block (Figure 1, Item 8). Install anchor bolt (Figure 1, Item 10) and nut (Figure 1, Item 9) on snatch block (Figure 1, Item 8) for storage.
0709-2
TM 9-2320-272-23-4
0709
REMOVAL - Continued
1 4 2 1 3 3 5
12
13
14 6 11 9 7
8 10
M9739DAA
Figure 1.
Hoist Winch Cable Removal.
0709-3
TM 9-2320-272-23-4
0709
REMOVAL - Continued 6. Thread cable clevis (Figure 2, Item 3) through forward boom sheaves (Figure 2, Item 2) until only one part of cable (Figure 2, Item 5) extends from forward boom sheaves.
NOTE
Direct assistant to maintain tension on cable while crane hoist is in operation. 7. Continue to unwind cable (Figure 2, Item 5) until screw (Figure 2, Item 4) on hoist winch drum (Figure 2, Item 6) is visible. Place hoist control in NEUTRAL position and shut down hoist winch operation (TM 9-2320-272-10). Remove screw (Figure 2, Item 4) and cable (Figure 2, Item 5) from hole (Figure 2, Item 7) in hoist winch drum (Figure 2, Item 6). Install screw (Figure 2, Item 4) in hoist winch drum (Figure 2, Item 6) for storage. Pull cable (Figure 2, Item 5) from boom (Figure 2, Item 1).
8. 9. 10.
2 5 4 3
5 7 1 6
6
M9740DAA
Figure 2. Hoist Winch Cable Removal. END OF TASK
0709-4
TM 9-2320-272-23-4
0709
INSTALLATION 1. 2. 3. 4. Thread cable end of cable (Figure 3, Item 4) over forward boom sheaves (Figure 3, Item 2) and through upper boom roller (Figure 3, Item 7). Thread cable (Figure 3, Item 4) around upper rear sheaves (Figure 3, Item 9) and lower rear sheaves (Figure 3, Item 8). Feed cable (Figure 3, Item 4) under boom (Figure 3, Item 1) to hoist winch drum (Figure 3, Item 5). Remove screw (Figure 3, Item 3), insert cable (Figure 3, Item 4) through hole (Figure 3, Item 6) in hoist winch drum (Figure 3, Item 5), and install screw.
1 2 4 3
4 6 5 1 9 4 8 2 7
M9741DAA
Figure 3.
Hoist Winch Cable Installation.
0709-5
TM 9-2320-272-23-4
0709
NOTE
Direct assistant to maintain tension on hoist cable and observe that cable is winding properly. 5. 6. 7. 8. 9. 10. 11. Wind cable (Figure 4, Item 2) on hoist winch drum (Figure 4, Item 1) until clevis (Figure 4, Item 3) end of cable (Figure 4, Item 2) leaves ground. Thread cable clevis (Figure 4, Item 3) through snatch block (Figure 4, Item 15), over forward boom sheave (Figure 4, Item 4), and back to snatch block. Remove nut (Figure 4, Item 14) and anchor bolt (Figure 4, Item 13) from snatch block (Figure 4, Item 15) and install cable clevis (Figure 4, Item 3) with anchor bolt and nut. Install two spacers (Figure 4, Item 16) on forward boom (Figure 4, Item 12) with two screws (Figure 4, Item 11) and locknuts (Figure 4, Item 8). Install rear cable guard (Figure 4, Item 7) over rear sheaves (Figure 4, Item 6) on boom (Figure 4, Item 5) with four washers (Figure 4, Item 8), lockwashers (Figure 4, Item 9), and screws (Figure 4, Item 10). Raise snatch block (Figure 4, Item 15) and place in stowage position (TM 9-2320-272-10). Place hoist control in NEUTRAL position and stop vehicle (TM 9-2320-272-10).
0709-6
TM 9-2320-272-23-4
0709
1 2 2
3 4
3 13 14
17 5 16
5 6 7
16 15
2 12 10 9 8
M9742DAA
11
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE Load test winch cable. (TB 9-352) END OF TASK END OF WORK PACKAGE
Hoist Winch Cable Installation.
0709-7/8 blank
TM 9-2320-272-23-4
0710
FIELD MAINTENANCE REAR WINCH CABLE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Rear winch cable unwound. (TM 9-2320-272-10)
REMOVAL
WARNING
Wear hand protection when handling winch cable. Do not handle cable with bare hands. Broken wires may be sharp. Failure to comply may result in injury or death to personnel. 1. Remove setscrew (Figure 1, Item 4) and cable (Figure 1, Item 2) from hole (Figure 1, Item 3) in winch drum (Figure 1, Item 1).
M5254DAA
Figure 1.
Rear Winch Cable Removal.
0710-1
TM 9-2320-272-23-4
0710
REMOVAL - Continued 2. Pull cable (Figure 2, Item 4) out over level wind pulley (Figure 2, Item 1), down through tensioner sheaves (Figure 2, Item 2), and out of rollers (Figure 2, Item 5), and side of rollers (Figure 2, Item 3).
1 2 2
3 4
5
M5255DAA
Figure 2. Rear Winch Cable Removal. END OF TASK INSTALLATION 1. Thread cable (Figure 3, Item 4) into center of side rollers (Figure 3, Item 3), rollers (Figure 3, Item 5), tensioner sheaves (Figure 3, Item 2), under level wind pulley plate (Figure 3, Item 1), and over level wind pulley (Figure 3, Item 6).
0710-2
TM 9-2320-272-23-4
0710
1 6 2 2
3 4
5
M9521DAA
Figure 3. 2.
Rear Winch Cable Installation.
Insert cable (Figure 4, Item 2) in hole (Figure 4, Item 3) of winch drum (Figure 4, Item 1) and install setscrew (Figure 4, Item 4).
1 2
M9522DAA
Rear Winch Cable Installation.
0710-3
TM 9-2320-272-23-4
0710
FOLLOW-ON MAINTENANCE Wind winch cable on drum. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0710-4
TM 9-2320-272-23-4
0711
FIELD MAINTENANCE WRECKER CRANE HYDRAULIC HOSE AND TUBE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Locknut (Volume 5, WP 0827, Table 1, Item 285) Qty: 6 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Shipper brace in travel position. (TM 9-2320-272-10) Hydraulic oil reservoir drained. (Volume 5, WP 0820)
0711-1
TM 9-2320-272-23-4
0711
REMOVAL
CAUTION
When disconnecting hydraulic hoses and tubes, plug all openings to prevent dirt from entering and causing internal parts damage.
NOTE
Do not twist hose during removal or attempt to remove hose with one wrench. Hose fitting ends connected by a single hexagonal nut cannot be disconnected until the flare nut connected at the opposite end is removed. The entire hose must be free to turn whenever removing hose connected by a single hexagonal nut. Tag all hoses and lines for installation. Have drainage container ready to catch oil. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. 1. 2. 3. 4. Remove locknut (Figure 1, Item 8), clamp (Figure 1, Item 2), hose (Figure 1, Item 7), and/or tube (Figure 1, Item 1) from bracket (Figure 1, Item 3) and wrecker body (Figure 1, Item 4). Discard locknut. Position wrenches on hexagonal fitting (Figure 1, Item 6) and flare nut (Figure 1, Item 5). Holding hexagonal fitting (Figure 1, Item 6) in place, loosen flare nut (Figure 1, Item 5), and disconnect hose (Figure 1, Item 7) and/or tube (Figure 1, Item 1) from hexagonal fitting. Repeat Steps (1) through (3) for remaining hoses (Figure 1, Item 7) and/or tubes (Figure 1, Item 1).
0711-2
TM 9-2320-272-23-4
0711
REMOVAL - Continued
2 3
4 8
1 2 5 6
5 7
M9737DAA
Figure 1. Wrecker Crane Hydraulic Hose and Tube Removal. END OF TASK
0711-3
TM 9-2320-272-23-4
0711
INSTALLATION
CAUTION
Ensure no particles of plugging become trapped in crane hydraulic system during installation of hoses or tubes. Failure to comply may result in damage to equipment.
NOTE
Do not twist hose or attempt to install hose with one wrench. Hose fitting ends connected by a single hexagonal nut cannot be connected until the hexagonal nut end is connected at the opposite end. The entire hose must be free to turn whenever installing hose connected by a single hexagonal nut. 1. 2. 3. 4. Install hose (Figure 2, Item 7) and/or tube (Figure 2, Item 1) on wrecker body (Figure 2, Item 4) and bracket (Figure 2, Item 3) with clamp (Figure 2, Item 2) and locknut (Figure 2, Item 8). Position wrenches on hexagonal fitting (Figure 2, Item 6) and flare nut (Figure 2, Item 5). Holding hexagonal fitting (Figure 2, Item 6) in place, tighten flare nut (Figure 2, Item 5). Repeat Steps (1) through (3) for remaining hoses (Figure 2, Item 7) and/or tubes (Figure 2, Item 1).
0711-4
TM 9-2320-272-23-4
0711
2 3
4 8
1 2 5 6
5 7
M9738DAA
Wrecker Crane Hydraulic Hose and Tube Installation.
0711-5/6 blank
TM 9-2320-272-23-4
0712
FIELD MAINTENANCE WRECKER CRANE HYDRAULIC PUMP REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Wrench, Torque, Click, Ratcheting, 1/2" Drive, 250 Ft-Lb (Volume 5, WP 0826, Table 1, Item 63) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Lockwasher (Volume 5, WP 0827, Table 1, Item 405) Qty: 16 Materials/Parts (cont.) O-ring (Volume 5, WP 0827, Table 1, Item 361) Qty: 1 O-ring (Volume 5, WP 0827, Table 1, Item 362) Qty: 1 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Hydraulic oil reservoir drained. (Volume 5, WP 0820)
0712-1
TM 9-2320-272-23-4
0712
REMOVAL
CAUTION
When disconnecting hydraulic hoses and lines, plug all openings to prevent dirt from entering and causing internal parts damage.
NOTE
Tag all hoses and lines for installation. Have drainage container ready to catch oil. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. 1. 2. 3. 4. Disconnect hose (Figure 1, Item 16) from hose (Figure 1, Item 15). Disconnect hoses (Figure 1, Item 13) and (Figure 1, Item 15) from inlet tee (Figure 1, Item 14). Disconnect hose (Figure 1, Item 7) from outlet elbow (Figure 1, Item 6). Remove four screws (Figure 1, Item 21), lockwashers (Figure 1, Item 22), and mount (Figure 1, Item 19) with crane pump (Figure 1, Item 10) from bracket (Figure 1, Item 1). Lower crane pump, and slide from driveshaft hub (Figure 1, Item 20). Discard lockwashers. Remove four screws (Figure 1, Item 17), lockwashers (Figure 1, Item 18), two split flanges (Figure 1, Item 12), inlet tee (Figure 1, Item 14), and o-ring (Figure 1, Item 11) from crane pump (Figure 1, Item 10). Discard lockwashers and o-ring. Remove four screws (Figure 1, Item 4), lockwashers (Figure 1, Item 3), two split flanges (Figure 1, Item 5), outlet elbow (Figure 1, Item 6), and o-ring (Figure 1, Item 8) from crane pump (Figure 1, Item 10). Discard lockwashers and o-ring. Remove four screws (Figure 1, Item 9), lockwashers (Figure 1, Item 2), and mount (Figure 1, Item 19) from crane pump (Figure 1, Item 10). Discard lockwashers.
5.
6.
7.
0712-2
TM 9-2320-272-23-4
0712
REMOVAL - Continued
4 3 22 21 2
8 9
20 19 12 18 17 11
10
12
16
13 15 15 14
M9735DAA
Wrecker Crane Hydraulic Pump Removal.
0712-3
TM 9-2320-272-23-4
0712
INSTALLATION 1. 2. Install mount (Figure 2, Item 19) on crane pump (Figure 2, Item 10) with four lockwashers (Figure 2, Item 2) and screws (Figure 2, Item 9). Install o-ring (Figure 2, Item 8) and outlet elbow (Figure 2, Item 6) on crane pump (Figure 2, Item 10) with two split flanges (Figure 2, Item 5), four lockwashers (Figure 2, Item 3), and screws (Figure 2, Item 4). Tighten screws 50 to 60 lb-ft (68 to 81 Nm). Install o-ring (Figure 2, Item 11) and inlet tee (Figure 2, Item 14) on crane pump (Figure 2, Item 10) with two split flanges (Figure 2, Item 12), four lockwashers (Figure 2, Item 18), and screws (Figure 2, Item 17). Tighten screws 50 to 60 lb-ft (68 to 81 Nm). Position shaft of crane pump (Figure 2, Item 10) on driveshaft hub (Figure 2, Item 20). Position mount (Figure 2, Item 19) with crane pump (Figure 2, Item 10) on bracket (Figure 2, Item 1) and install with four lockwashers (Figure 2, Item 22) and screws (Figure 2, Item 21). Connect hose (Figure 2, Item 7) to outlet elbow (Figure 2, Item 6). Connect hoses (Figure 2, Items 13 and 15) to inlet tee (Figure 2, Item 14). Connect hose (Figure 2, Item 16) to hose (Figure 2, Item 15).
3.
4. 5. 6. 7. 8.
0712-4
TM 9-2320-272-23-4
0712
4 3 22 21 2
8 9
20 19 12 18 17 11
10
12
16
13 15 15 14
M9736DAA
Figure 2. Wrecker Crane Hydraulic Pump Installation. END OF TASK
0712-5
TM 9-2320-272-23-4
0712
FOLLOW-ON MAINTENANCE 1. 2. Fill hydraulic oil reservoir to proper fluid level. (Volume 5, WP 0820) Check crane hydraulic pump for proper operation. (TM 9-2320-270-10)
0712-6
TM 9-2320-272-23-4
0713
FIELD MAINTENANCE TRANSMISSION PTO-TO-HYDRAULIC PUMP PROPELLER SHAFT REPAIR
REMOVAL 1. Remove setscrews (Figure 1, Items 3 and 5) and propeller shaft (Figure 1, Item 2) from PTO shaft (Figure 1, Item 1) and hydraulic pump shaft (Figure 1, Item 4).
3 1 2
5
Figure 1.
M5266DAA
Transmission PTO-To-Hydraulic Pump Propeller Shaft Removal.
0713-1
TM 9-2320-272-23-4
0713
REMOVAL - Continued
NOTE
This procedure covers maintenance for both universal joints. 2. Position propeller shaft (Figure 2, Item 1) in soft-jawed vise (Figure 2, Item 3) so end yoke (Figure 2, Item 2) moves freely.
2 1 3
M9629DAA
Figure 2. Transmission PTO-To-Hydraulic Pump Propeller Shaft Removal. 3. Position four lockrings (Figure 3, Item 4) from universal joint (Figure 3, Item 3).
NOTE
Do not drop bearing cups. Needle bearings inside are very small and can easily be lost. 4. 5. 6. Remove two bearing cups (Figure 3, Item 2) and end yoke (Figure 3, Item 7) from propeller shaft yoke (Figure 3, Item 1). Remove two bearing cups (Figure 3, Item 5) and universal joint (Figure 3, Item 3) from propeller shaft yoke (Figure 3, Item 1). Remove grease fitting (Figure 3, Item 6) from universal joint (Figure 3, Item 3).
0713-2
TM 9-2320-272-23-4
0713
REMOVAL - Continued
1 4 2 3 5 6 7
5 2
M9628DAA
Figure 3. 7. 8. 9.
Remove dust cap (Figure 4, Item 2) and slip yoke (Figure 4, Item 5) from propeller shaft splines (Figure 4, Item 1). Remove dust cap (Figure 4, Item 2), nylon washer (Figure 4, Item 3), and felt washer (Figure 4, Item 4) from slip yoke (Figure 4, Item 5). Discard felt washer, nylon washer, and dust cap. Remove grease fitting (Figure 4, Item 6) from slip yoke (Figure 4, Item 5).
6
5 4 3 2 1
M5269DAA
0713-3
TM 9-2320-272-23-4
0713
INSPECTION 1. 2. 3. Inspect bearing cups for worn or missing needle bearings. Replace needle bearings if worn or missing. Apply a few drops of lubricating oil in bearing cups. Using finger, roll needle bearings around to check for free movement. Replace bearing cup(s) if needle bearing movement is rough or uneven. Inspect end yoke, propeller shaft yoke, slip yoke, and universal joint for scoring, burrs, cracks, and bends. Replace part(s) if defective.
END OF TASK ASSEMBLY 1. Install grease fitting (Figure 5, Item 6) on slip yoke (Figure 5, Item 5).
NOTE
Soak felt washer in lubricating oil prior to installation. 2. 3. 4. Slide dust cap (Figure 5, Item 2), nylon washer (Figure 5, Item 3), felt washer (Figure 5, Item 4), and slip yoke (Figure 5, Item 5) over propeller shaft splines (Figure 5, Item 1). Install nylon washer (Figure 5, Item 3) and felt washer (Figure 5, Item 4) in dust cap (Figure 5, Item 2). Install dust cap (Figure 5, Item 2) on slip yoke (Figure 5, Item 5).
6
5 4 3 2 1
M9630DAA
Figure 5. Transmission PTO-To-Hydraulic Pump Propeller Shaft Assembly.
0713-4
TM 9-2320-272-23-4
0713
ASSEMBLY - Continued 5. Place propeller shaft (Figure 6, Item 1) in soft-jawed vise (Figure 6, Item 3) so end yoke (Figure 6, Item 2) moves freely.
2 1 3
M5267DAA
0713-5
TM 9-2320-272-23-4
0713
ASSEMBLY - Continued 6. Install grease fitting (Figure 7, Item 6) on universal joint (Figure 7, Item 3).
NOTE
Lubricate new or used universal joint before assembly. Press bearing cups into yoke far enough to install lockrings. 7. 8. 9. Place universal joint (Figure 7, Item 3) in propeller shaft yoke (Figure 7, Item 1). Install two bearing cups (Figure 7, Item 2) on universal joint (Figure 7, Item 3) and end yoke (Figure 7, Item 7) with two lockrings (Figure 7, Item 4). Install two bearing cups (Figure 7, Item 5) on universal joint (Figure 7, Item 3) and propeller shaft yoke (Figure 7, Item 1) with two lockrings (Figure 7, Item 4).
1 4 2 3 5 6 7
5 2
M9627DAA
0713-6
TM 9-2320-272-23-4
0713
ASSEMBLY - Continued 10. Remove propeller shaft (Figure 8, Item 1) from soft-jawed vise (Figure 8, Item 3).
1 2
M10194DAA
Figure 8. Transmission PTO-To-Hydraulic Pump Propeller Shaft Assembly. END OF TASK
0713-7
TM 9-2320-272-23-4
0713
INSTALLATION 1. Position universal joint ends (Figure 9, Item 3) of propeller shaft (Figure 9, Item 4) over PTO shaft (Figure 9, Item 2) and hydraulic pump shaft (Figure 9, Item 8). Ensure universal joint ends are seated properly over woodruff keys (Figure 9, Item 6) of PTO shaft and hydraulic pump shaft. Install propeller shaft (Figure 9, Item 4) on PTO shaft (Figure 9, Item 2) and hydraulic pump shaft (Figure 9, Item 8) with setscrews (Figure 9, Items 5 and 9). Ensure setscrews seat properly in shaft channels (Figure 9, Items 1 and 7).
3 1 2 3 4 5
2.
6 9 8 7
M5265DAA
Figure 9. Transmission PTO-To-Hydraulic Pump Propeller Shaft Installation. END OF TASK FOLLOW-ON MAINTENANCE Start engine (TM 9-2320-272-10) and operate any accessory driven by the transmission PTO-to-hydraulic pump propeller shaft. Stop engine (TM 9-2320-272-10) and check for looseness. END OF TASK END OF WORK PACKAGE
0713-8
TM 9-2320-272-23-4
0714
FIELD MAINTENANCE TRANSFER PTO-TO-HYDRAULIC PUMP PROPELLER SHAFT REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Jack Dolly Type Hydraulic (Volume 5, WP 0826, Table 1, Item 32) Materials/Parts Lockwasher Materials/Parts (cont.) (Volume 5, WP 0827, Table 1, Item 405) Qty: 4 Lockwasher (Volume 5, WP 0827, Table 1, Item 444) Qty: 4 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0714-1
TM 9-2320-272-23-4
0714
REMOVAL
NOTE
Transfer PTO-to-crane hydraulic pump propeller shaft and adapter come assembled as one unit but adapter must be replaced separately. 1. 2. 3. 4. 5. 6. 7. Remove four nuts (Figure 1, Item 3), lockwashers (Figure 1, Item 4), and screws (Figure 1, Item 5) from propeller shaft (Figure 1, Item 14) and driveshaft flange (Figure 1, Item 17). Discard lockwashers. Rotate propeller shaft (Figure 1, Item 14) to position lubrication fitting (Figure 1, Item 6) at top. Support weight of pump (Figure 1, Item 9) with hydraulic jack. Remove four screws (Figure 1, Item 8) and lockwashers (Figure 1, Item 7) from pump (Figure 1, Item 9) and mount (Figure 1, Item 12). Discard lockwashers. Separate pump (Figure 1, Item 9) from mount (Figure 1, Item 12) and slide toward rear of vehicle until pump boss (Figure 1, Item 10) clears mount. Lower hydraulic jack enough to allow separation and removal of propeller shaft (Figure 1, Item 14) from pump shaft (Figure 1, Item 11). Remove nut (Figure 1, Item 15) and washer (Figure 1, Item 16) from transfer PTO shaft (Figure 1, Item 2) and slide driveshaft flange (Figure 1, Item 17) off transfer PTO shaft (Figure 1, Item 1).
7 3 1 2 4 5 6
8 9
17 16 15
14
13 12
11 10
M9049DAA
Transfer PTO-to-Hydraulic Pump Propeller Shaft Removal.
0714-2
TM 9-2320-272-23-4
0714
INSTALLATION 1. 2. Install driveshaft flange (Figure 2, Item 17) on transfer PTO shaft (Figure 2, Item 2) with washer (Figure 2, Item 16) and nut (Figure 2, Item 15). Raise hydraulic jack enough to position pump shaft (Figure 2, Item 11) and boss (Figure 2, Item 10) of pump (Figure 2, Item 9) through mount (Figure 2, Item 12). Ensure rear hub of propeller shaft (Figure 2, Item 14) slides on pump shaft. Position propeller shaft (Figure 2, Item 14) on PTO shaft (Figure 2, Item 1) with lubrication fitting (Figure 2, Item 6) positioned at top. Install propeller shaft (Figure 2, Item 14) on driveshaft flange (Figure 2, Item 17) with four screws (Figure 2, Item 5), lockwashers (Figure 2, Item 4), and nuts (Figure 2, Item 3). Install pump (Figure 2, Item 9) on mount (Figure 2, Item 12) with four lockwashers (Figure 2, Item 7) and screws (Figure 2, Item 8). Tighten screws 32 to 40 lb-ft (43 to 54 Nm).
3. 4. 5.
7 3 1 2 4 5 6
8 9
17 16 15
14
13 12
11 10
M9050DAA
Figure 2. Transfer PTO-to-Hydraulic Pump Propeller Shaft Installation. END OF TASK FOLLOW-ON MAINTENANCE Check operation of crane hydraulic system. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0714-3/4 blank
TM 9-2320-272-23-4
0715
FIELD MAINTENANCE DUMP BODY HYDRAULIC HOSE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Dump body in lowered position. (TM 9-2320-272-10) Hydraulic oil reservoir drained. (Volume 5, WP 0820)
0715-1
TM 9-2320-272-23-4
0715
REMOVAL
WARNING
Never work under dump body until safety braces are properly positioned. Dump body may suddenly lower. Failure to comply may result in injury or death to personnel. Ensure dump control lever is in the NEUTRAL position and has not moved. Failure to comply may result in injury or death to personnel. Accidental or intentional introduction of liquid contaminants into the environment is in violation of state, federal, and military regulations. Refer to local Unit SOP for information concerning storage, use, and disposal of these liquids. Failure to comply may result in injury or death to personnel. Do not remove hoses with engine running or start engine with hoses removed. Highpressure fluids may cause hoses to whip violently and spray randomly. Failure to comply may result in injury or death to personnel.
NOTE
All hydraulic hoses are removed the same way. This procedure covers dump hoist cylinder and safety lock hoses only. 1. 2. Place dump body in raised position (TM 9-2320-272-10). Place safety braces in proper position (TM 9-2320-272-10).
CAUTION
Plug all hydraulic lines or openings to prevent dirt from entering and damaging components.
NOTE
Cross fittings to hoist cylinder hoses must be disconnected from the cross fittings first. Then hoses can be removed from hoist cylinders. Have drainage container ready to catch oil. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. Drain hoses before plugging. Tag hoses for installation. 3. 4. 5. 6. 7. Disconnect four hydraulic hoses (Figure 1, Items 5, 9, 11, and 13) from right cross fitting (Figure 1, Item 10). Disconnect four hydraulic hoses (Figure 1, Items 4, 6, 8, and 12) from left cross fitting (Figure 1, Item 7). Disconnect two hydraulic hoses (Figure 1, Items 5 and 11) from right and left cylinder ports (Figure 1, Items 1 and 15). Disconnect two hydraulic hoses (Figure 1, Items 6 and 12) from right and left cylinder ports (Figure 1, Items 3 and 14). Disconnect two hydraulic hoses (Figure 1, Items 4 and 13) from safety lock cylinder (Figure 1, Item 2).
0715-2
TM 9-2320-272-23-4
0715
REMOVAL - Continued
1 15
14
13 12 5
11
10
M3019DAA
Figure 1.
Hydraulic Hoses.
0715-3
TM 9-2320-272-23-4
0715
REMOVAL - Continued
NOTE
All dump body hoses are removed the same, two of nine hoses shown. Refer to Figure 3 for removal and routing of remaining dump body hydraulic hoses. 8. 9. Disconnect two hydraulic hoses (Figure 2, Items 3 and 4) from fittings (Figure 2, Items 1 and 2). Disconnect two hydraulic hoses (Figure 2, Items 3 and 4) from control valve (Figure 2, Item 7) and fittings (Figure 2, Items 5 and 6).
4 6 3 5 3 4
M10356DAA
Figure 2.
Hydraulic Hoses.
0715-4
TM 9-2320-272-23-4
0715
REMOVAL - Continued
LEFT TEE TO CYLINDER SAFETY SAFETY LOCK LOCK CYLINDER
PUMP TO TANK VALVE TO FILTER
VALVE TO LEFT TEE
VALVE TO PUMP
VALVE TO RIGHT TEE
RIGHT TEE TO CYLINDER

M10386DAA
Hydraulic Hoses.
0715-5
TM 9-2320-272-23-4
0715
INSTALLATION
NOTE
Ensure plugs are removed from all fittings before installation. Ensure no particles of plugging become trapped in dump body hydraulic system during installation of hoses and tubing. All dump body hydraulic hoses are installed the same, two of nine hoses shown. Refer to Figure 5 for installation and routing of remaining dump body hydraulic hoses. 1. 2. Connect two hydraulic hoses (Figure 4, Items 3 and 4) to fittings (Figure 4, Items 5 and 6) on control valve (Figure 4, Item 7). Connect two hydraulic hoses (Figure 4, Items 3 and 4) to cross fittings (Figure 4, Items 1 and 2).
4 6 3 5 3 4
M3021DAA
Figure 4.
Hydraulic Hoses.
0715-6
TM 9-2320-272-23-4
0715
PUMP TO TANK VALVE TO FILTER
LEFT TEE TO CYLINDER SAFETY SAFETY LOCK LOCK CYLINDER
VALVE TO LEFT TEE
VALVE TO PUMP
VALVE TO RIGHT TEE
RIGHT TEE TO CYLINDER

M10387DAA
Figure 5.
Hydraulic Hoses.
0715-7
TM 9-2320-272-23-4
0715
INSTALLATION - Continued 3. Connect two hydraulic hoses (Figure 6, Items 9 and 13) to right and left cylinder ports (Figure 6, Items 17 and 18) (with bypass tube (Figure 6, Items 1 and 3) extending full length of cylinder) and right cross fitting (Figure 6, Item 12). Connect two hydraulic hoses (Figure 6, Items 10 and 14) to right and left cylinder ports (Figure 6, Items 7 and 16) (with bypass tube (Figure 6, Items 2 and 4) extending midway of the cylinder) and left cross fitting (Figure 6, Item 11). Connect left cross fitting-to-safety lock cylinder hose (Figure 6, Item 8) to left safety lock cylinder port (Figure 6, Item 6) and left cross fitting (Figure 6, Item 11). Connect right cross fitting-to-safety lock cylinder hose (Figure 6, Item 15) to right safety lock cylinder port (Figure 6, Item 5) and right cross fitting (Figure 6, Item 12). Remove dump body safety braces and place in lowest position (Volume 5, WP 0820).
1 2 3 4
4.
5. 6. 7.
17
5 6 7
16
18
15 14
13 9
12
10
11
M3022DAA
Hydraulic Hoses.
0715-8
TM 9-2320-272-23-4
0715
FOLLOW-ON MAINTENANCE 1. 2. Fill hydraulic reservoir to proper oil level. (Volume 5, WP 0820) Start engine and operate through full range. Check for leaks and proper operation. (TM 9-2320-272-10)
0715-9/10 blank
TM 9-2320-272-23-4
0716
FIELD MAINTENANCE DUMP VALVE CABLE AND SHIFT LEVER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin (Volume 5, WP 0827, Table 1, Item 340) Qty: 2 Locknut (Volume 5, WP 0827, Table 1, Item 256) Qty: 6 Locknut (Volume 5, WP 0827, Table 1, Item 282) Qty: 3 Locknut (Volume 5, WP 0827, Table 1, Item 285) Qty: 14 Locknut (Volume 5, WP 0827, Table 1, Item 289) Qty: 1 Tiedown Strap (Volume 5, WP 0827, Table 1, Item 379) Qty: 1 Personnel Required (2) References Volume 5, WP 0820 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0716-1
TM 9-2320-272-23-4
0716
REMOVAL 1. 2. Remove cotter pin (Figure 1, Item 13), washer (Figure 1, Item 38), and clevis pin (Figure 1, Item 39) from cable clevis (Figure 1, Item 25) and shift lever arm (Figure 1, Item 6). Discard cotter pin. Remove four locknuts (Figure 1, Item 12), screws (Figure 1, Item 9), and shift lever (Figure 1, Item 10) from two shift lever brackets (Figure 1, Item 8), shims (Figure 1, Item 11), and floor (Figure 1, Item 41). Discard locknuts. Remove woodruff key (Figure 1, Item 4) from shift lever rod (Figure 1, Item 10). Remove locknut (Figure 1, Item 7), screw (Figure 1, Item 5), and shift lever arm (Figure 1, Item 6) from cab floor (Figure 1, Item 41). Discard locknut. Remove two shift lever brackets (Figure 1, Item 8) from shift lever rod (Figure 1, Item 10). Remove six locknuts (Figure 1, Item 40), screws (Figure 1, Item 3), seal (Figure 1, Item 2), and retainer ring (Figure 1, Item 1) from cab floor (Figure 1, Item 41). Discard locknuts. Loosen and remove cable clevis (Figure 1, Item 25) and jamnut (Figure 1, Item 24) from dump valve cable (Figure 1, Item 32). Remove two locknuts (Figure 1, Item 21), screws (Figure 1, Item 27), clamp (Figure 1, Item 26), and shim (Figure 1, Item 23) from cable conduit (Figure 1, Item 28) and rear cab floor left bracket (Figure 1, Item 22). Discard locknuts. Remove locknut (Figure 1, Item 20), screw (Figure 1, Item 30), and clamp (Figure 1, Item 29) from cable conduit (Figure 1, Item 28) and rear cab floor right bracket (Figure 1, Item 19). Discard locknut. Remove tiedown strap (Figure 1, Item 31) from cable conduit (Figure 1, Item 28). Discard tiedown strap. Remove cotter pin (Figure 1, Item 17), washer (Figure 1, Item 16), and clevis pin (Figure 1, Item 15) from cable clevis (Figure 1, Item 14) and control valve (Figure 1, Item 18). Discard cotter pin. Loosen and remove cable clevis (Figure 1, Item 14) and jamnut (Figure 1, Item 37) from dump valve cable (Figure 1, Item 32). Remove jamnut (Figure 1, Item 37) and washer (Figure 1, Item 36) from control valve (Figure 1, Item 18) side of cable conduit (Figure 1, Item 28) and lower bracket (Figure 1, Item 35). Pull cable conduit (Figure 1, Item 28) through lower bracket (Figure 1, Item 35). Remove washer (Figure 1, Item 34) and nut (Figure 1, Item 33) from cable conduit. Tag for installation.
3. 4. 5. 6. 7. 8.
9. 10. 11. 12. 13. 14.
0716-2
TM 9-2320-272-23-4
0716
REMOVAL - Continued
9 10
4 3 2 1 41 40 11 8 12 11
39 28 38 25 14 37 36 33 32 28 31 34 35 17 18 15 16 13
19 20 21 30 29 26 28
22
23
24 25
27
Valve Cable and Shift Lever Removal.
M3023DAA
0716-3
TM 9-2320-272-23-4
0716
INSTALLATION AND ADJUSTMENT 1. 2. Install nut (Figure 2, Item 33) and washer (Figure 2, Item 34) on cable conduit (Figure 2, Item 28). Place control valve (Figure 2, Item 18) end of cable conduit (Figure 2, Item 28) through lower bracket (Figure 2, Item 35), and install cable conduit on lower bracket with washer (Figure 2, Item 36) and jamnut (Figure 2, Item 37). Install cable clevis (Figure 2, Item 14) on control valve (Figure 2, Item 18) end of valve cable (Figure 2, Item 32) with four turns. Route cable conduit (Figure 2, Item 28) under cab floor (Figure 2, Item 41). Install retainer ring (Figure 2, Item 1) and seal (Figure 2, Item 2) on cab floor (Figure 2, Item 41) with six screws (Figure 2, Item 3) and locknuts (Figure 2, Item 40). Slide two lever brackets (Figure 2, Item 8) on lever rod (Figure 2, Item 10). Install woodruff key (Figure 2, Item 4) on lever rod (Figure 2, Item 10), and slide arm (Figure 2, Item 6) over lever rod and woodruff key. Install screw (Figure 2, Item 5) and locknut (Figure 2, Item 7) on arm (Figure 2, Item 6). Position shift lever rod (Figure 2, Item 10) on cab floor (Figure 2, Item 41), and install lever rod, two brackets (Figure 2, Item 8), and shims (Figure 2, Item 11) with four screws (Figure 2, Item 9) and locknuts (Figure 2, Item 12). Install cable clevis (Figure 2, Item 25) on lever arm (Figure 2, Item 6) with clevis pin (Figure 2, Item 39), washer (Figure 2, Item 38), and cotter pin (Figure 2, Item 13). Install cable conduit (Figure 2, Item 28) and two shims (Figure 2, Item 23) on rear cab bracket (Figure 2, Item 22) with two clamps (Figure 2, Item 26), screws (Figure 2, Item 27), and locknuts (Figure 2, Item 21). Install cable conduit (Figure 2, Item 28) on front cab bracket (Figure 2, Item 19) with clamp (Figure 2, Item 29), screw (Figure 2, Item 30), and locknut (Figure 2, Item 20). Place shift lever in down position (TM 9-2320-272-10). Pull valve shaft (Figure 2, Item 18) out manually until seated. Valve shaft will stop when seated.
3. 4. 5. 6. 7. 8. 9.
10. 11.
12. 13. 14.
NOTE
Cable throw length can be adjusted with jamnut. 15. 16. 17. Align hole of clevis pin (Figure 2, Item 15) and hole of cable clevis (Figure 2, Item 14) with hole in valve shaft (Figure 2, Item 18). Use jamnuts (Figure 2, Items 33 and 37). Back off clevis (Figure 2, Item 14) one turn and install on valve shaft (Figure 2, Item 18) with clevis pin (Figure 2, Item 15), washer (Figure 2, Item 16), and cotter pin (Figure 2, Item 17). Install tiedown strap (Figure 2, Item 31) on cable conduit (Figure 2, Item 28).
0716-4
TM 9-2320-272-23-4
0716
INSTALLATION AND ADJUSTMENT - Continued
9 10
4 3 2 1 41 40 11 8 12 11
39 28 38 25 14 37 36 33 32 28 31 34 35 17 18 15 16 13
19 20 21 30 29 26 28
22
23
24 25
27
M3024DAA
Valve Cable and Shift Lever Installation.
0716-5
TM 9-2320-272-23-4
0716
FOLLOW-ON MAINTENANCE 1. 2. Lubricate shift lever. (Volume 5, WP 0820) Test dump cable operation. (TM 9-2320-272-10)
0716-6
TM 9-2320-272-23-4
0717
FIELD MAINTENANCE DUMP SUBFRAME REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Cotter Pin (Volume 5, WP 0827, Table 1, Item 349) Qty: 4 Locknut (Volume 5, WP 0827, Table 1, Item 279) Qty: 8 Personnel Required (3) Equipment Condition Parking brake set. (TM 9-2320-272-10) Hydraulic oil reservoir drained. (Volume 5, WP 0820) Dump body removed. (WP 0594)
0717-1
TM 9-2320-272-23-4
0717
REMOVAL
WARNING
Accidental or intentional introduction of liquid contaminants into the environment is in violation of state, federal, and military regulations. Refer to local Unit SOP for information concerning storage, use, and disposal of these liquids. Failure to comply may result in injury or death to personnel. Do not remove hoses with engine running or start engine with hoses removed. Highpressure fluids may cause hoses to whip violently and spray randomly. Failure to comply may result in injury or death to personnel.
CAUTION
Plug all hydraulic lines or openings to prevent dirt from entering and damaging components.
NOTE
Have container ready to catch oil from hydraulic tubes, lines, and hoses. Drain hoses before plugging. Tag hoses for installation. 1. 2. Disconnect pump-to-reservoir hydraulic tube (Figure 1, Item 2) from pump adapter (Figure 1, Item 6) and reservoir adapter (Figure 1, Item 1). Disconnect filter-to-reservoir hydraulic hose (Figure 1, Item 3) from filter elbow (Figure 1, Item 4) and reservoir adapter (Figure 1, Item 5).
0717-2
TM 9-2320-272-23-4
0717
REMOVAL - Continued
2 6 2
M3025DAA
Figure 1.
Dump Subframe Removal.
0717-3
TM 9-2320-272-23-4
0717
REMOVAL - Continued
NOTE
Cross fittings to hoist cylinder hoses must be disconnected from the cross fittings first. Then hoses can be removed from hoist cylinders. Have drainage container ready to catch oil. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. Tag hoses for installation. 3. 4. 5. 6. 7. Disconnect three hydraulic hoses (Figure 2, Items 6, 7, and 11) from right cross fitting (Figure 2, Item 10). Disconnect three hydraulic hoses (Figure 2, Items 5, 8, and 12) from left cross fitting (Figure 2, Item 9). Disconnect two hydraulic hoses (Figure 2, Items 7 and 11) from right and left cylinder ports (Figure 2, Items 2 and 13). Disconnect two hydraulic hoses (Figure 2, Items 8 and 12) from right and left cylinder ports (Figure 2, Items 1 and 4). Disconnect two hydraulic hoses (Figure 2, Items 5 and 6) from safety lock cylinder (Figure 2, Item 3).
0717-4
TM 9-2320-272-23-4
0717
REMOVAL - Continued
13
12 6 5
11 7
10
M3026DAA
Figure 2.
0717-5
TM 9-2320-272-23-4
0717
REMOVAL - Continued 8. 9. 10. 11. Remove eight locknuts (Figure 3, Item 6), screws (Figure 3, Item 7), and two rear holddown brackets (Figure 3, Item 5) from frame (Figure 3, Item 8). Discard locknuts. Attach two utility chains to frame channel (Figure 3, Item 4). Attach lifting device to center of two utility chains and remove slack from utility chain. Remove two cotter pins (Figure 3, Item 11), slotted nuts (Figure 3, Item 12), washer (Figure 3, Item 13), screws (Figure 3, Item 18), upper half-keeper (Figure 3, Item 17), spring (Figure 3, Item 16), and lower half-keeper (Figure 3, Item 15) from two front holddown brackets (Figure 3, Item 14) and frame (Figure 3, Item 8). Discard cotter pins. Connect two guide lines (Figure 3, Item 10) to front and rear of subframe (Figure 3, Item 1).
12.
WARNING
NOTE
Mechanic will handle one guide line and direct hoisting operation. Assistant will handle other guide line. Second assistant will operate lifting device. 13. 14. Lift subframe (Figure 3, Item 1) clear of frame (Figure 3, Item 8) and place on two shop stands (Figure 3, Item 9). Remove guide lines, lifting device, and utility chains from subframe (Figure 3, Item 1).
0717-6
TM 9-2320-272-23-4
0717
REMOVAL - Continued
18 17 16 15 14 1 2 3 4
13 12 11
7 10
8 9
M3027DAA
0717-7
TM 9-2320-272-23-4
0717
INSTALLATION 1. 2. 3. Attach two utility chains (Figure 4, Item 3) to subframe (Figure 4, Item 1). Attach lifting device (Figure 4, Item 2) to center of two utility chains (Figure 4, Item 3) and remove slack from utility chain. Connect two guide lines (Figure 4, Item 10) to front and rear of subframe (Figure 4, Item 1).
WARNING
NOTE
Mechanic will handle one guide line and direct hoisting operation. Assistant will handle other guide line. Second assistant will operate lifting device. 4. 5. 6. 7. 8. Lift subframe (Figure 4, Item 1) clear of two shop stands (Figure 4, Item 9) and lower onto frame (Figure 4, Item 8). Using drift pin, align holes in brackets (Figure 4, Items 5 and 14). Install two rear holddown brackets (Figure 4, Item 5) on frame (Figure 4, Item 8) with eight screws (Figure 4, Item 7) and locknuts (Figure 4, Item 6). Remove guide lines (Figure 4, Item 10), lifting device (Figure 4, Item 2), and utility chains (Figure 4, Item 3) from subframe (Figure 4, Item 1). Install two front holddown brackets (Figure 4, Item 14) on frame (Figure 4, Item 8) with lower half-keeper (Figure 4, Item 15), spring (Figure 4, Item 16), upper half-keeper (Figure 4, Item 17), screw (Figure 4, Item 18), washer (Figure 4, Item 13), slotted nut (Figure 4, Item 12), and cotter pin (Figure 4, Item 11).
0717-8
TM 9-2320-272-23-4
0717
18 17 16 15 14 1 2 3 4
13 12 11
7 10
8 9
M3028DAA
Figure 4.
Dump Subframe Installation.
0717-9
TM 9-2320-272-23-4
0717
INSTALLATION - Continued 9. 10. 11. 12. 13. 14. Connect two hydraulic hoses (Figure 5, Item 10) to left and right cylinder ports (Figure 5, Item 12) (with bypass tube (Figure 5, Item 1) which extends full length of cylinder) and right cross fitting (Figure 5, Item 9). Connect two hydraulic hoses (Figure 5, Item 7) to left and right cylinder ports (Figure 5, Item 5) (with bypass tube (Figure 5, Item 2) which extends to middle of the cylinder) and left cross fitting (Figure 5, Item 8). Connect left cross fitting-to-safety lock cylinder hose (Figure 5, Item 6) to left safety lock cylinder port (Figure 5, Item 4) and left cross fitting (Figure 5, Item 8). Connect right cross fitting-to-safety lock cylinder hose (Figure 5, Item 11) to right safety lock cylinder port (Figure 5, Item 3), and right cross fitting (Figure 5, Item 9). Connect filter-to-reservoir hydraulic tube (Figure 5, Item 14) to filter adapter (Figure 5, Item 15) and reservoir elbow (Figure 5, Item 13). Connect pump-to-reservoir hydraulic tube (Figure 5, Item 17) to pump adapter (Figure 5, Item 18) and reservoir adapter (Figure 5, Item 16).
13 1 2 3 1 2
14
4 15 12 7 11 7 10 9 8 5 12 10 6 16 5
18
Figure 5. Dump Subframe Installation. END OF TASK
17
M3029DAA
0717-10
TM 9-2320-272-23-4
0717
FOLLOW-ON MAINTENANCE 1. 2. 3. Install dump body. (WP 0594) Fill hydraulic reservoir to proper oil level. (Volume 5, WP 0820) Start engine and operate through full range. Check for leaks and proper operation. (TM 9-2320-272-10)
0717-11/12 blank
TM 9-2320-272-23-4
0718
FIELD MAINTENANCE DUMP SAFETY BRACE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Dump body in lowered position. (TM 9-2320-272-10)
0718-1
TM 9-2320-272-23-4
0718
REMOVAL
NOTE
Both left and right safety braces are removed in the same way. This procedure applies to left brace only. 1. 2. 3. Remove nut (Figure 1, Item 3), washer (Figure 1, Item 2), and screw (Figure 1, Item 1) from safety brace hinge pin (Figure 1, Item 5). Using chisel and hammer, remove safety brace hinge pin (Figure 1, Item 5) from bracket (Figure 1, Item 6) and safety brace (Figure 1, Item 4). Remove safety brace (Figure 1, Item 4) from bracket (Figure 1, Item 6).
1 2 6 3 5
M3013DAA
Dump Safety Brace Removal.
0718-2
TM 9-2320-272-23-4
0718
INSTALLATION 1. 2. Install safety brace (Figure 2, Item 4) on bracket (Figure 2, Item 6). Align holes in safety brace (Figure 2, Item 4) and bracket (Figure 2, Item 6), and install safety brace hinge pin (Figure 2, Item 5) with screw (Figure 2, Item 1), washer (Figure 2, Item 2), and nut (Figure 2, Item 3).
1 2 6 3 5
M3014DAA
Dump Safety Brace Installation.
0718-3/4 blank
TM 9-2320-272-23-4
0719
FIELD MAINTENANCE DUMP HYDRAULIC PUMP REPLACEMENT
INITIAL SETUP: References WP 0683
REPLACEMENT Procedure for replacement of the dump hydraulic pump can be found in Front Winch Hydraulic Pump Replacement (WP 0683). END OF TASK END OF WORK PACKAGE
0719-1/2 blank
TM 9-2320-272-23-4
0720
FIELD MAINTENANCE DUMP CONTROL VALVE REPLACEMENT
INITIAL SETUP: References WP 0721
REPLACEMENT Procedure for replacement of the dump control valve can be found in Front and Rear Winch Control Valve (M930/A1/A2) Replacement (WP 0721). END OF TASK END OF WORK PACKAGE
0720-1/2 blank
TM 9-2320-272-23-4
0721
FIELD MAINTENANCE FRONT AND REAR WINCH CONTROL VALVE REPLACEMENT (M930/A1/A2)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Cotter Pin (Volume 5, WP 0827, Table 1, Item 340) Qty: 2 Locknut (Volume 5, WP 0827, Table 1, Item 285) Qty: 3 O-ring (Volume 5, WP 0827, Table 1, Item 80) Qty: 4 Materials/Parts (cont.) O-ring (Volume 5, WP 0827, Table 1, Item 164) Qty: 1 O-ring (Volume 5, WP 0827, Table 1, Item 364) Qty: 2 References Volume 5, WP 0820 Equipment Condition Parking brake set. (TM 9-2320-272-10) Hydraulic oil reservoir drained. (WP 0703)
0721-1
TM 9-2320-272-23-4
0721
REMOVAL
CAUTION
Plug all hydraulic hoses to prevent dirt from entering.
NOTE
Front and rear winch control valves are replaced basically the same. This procedure covers the front winch control valve. Tag all hoses and fittings for installation. 1. Disconnect hoses (Figure 1, Items 2, 4, 5, 6, 7, and 17) from control valve (Figure 1, Item 8).
NOTE
Both upper and lower cable clevises are removed the same way. 2. 3. 4. Remove cotter pin (Figure 1, Item 15), washer (Figure 1, Item 14), and clevis pin (Figure 1, Item 3) from two cable clevises (Figure 1, Item 1). Discard cotter pin. Remove three locknuts (Figure 1, Item 13), screws (Figure 1, Item 12), and control valve (Figure 1, Item 8) from bracket (Figure 1, Item 10). Discard locknuts. Remove four nuts (Figure 1, Item 9), screws (Figure 1, Item 11), and bracket (Figure 1, Item 10) from frame (Figure 1, Item 16).
17 1 2 3 4 5
1 16 15 14 12 13 8 11 10 9
M6027DAA
Figure 1.
0721-2
TM 9-2320-272-23-4
0721
REMOVAL - Continued 5. 6. 7. 8. Remove elbows (Figure 2, Items 2 and 5) and adapter (Figure 2, Item 10) from valve fittings (Figure 2, Items 1 and 4) and elbow (Figure 2, Item 11). Remove fittings (Figure 2, Items 1, 4, and 14) and elbows (Figure 2, Items 3, 11, and 15) from control valve (Figure 2, Item 13). Remove six o-rings (Figure 2, Item 12) from fittings (Figure 2, Items 1, 4, and 14) and elbows (Figure 2, Items 3 and 11). Discard o-rings. Remove plug (Figure 2, Item 6), o-ring (Figure 2, Item 7), spring (Figure 2, Item 8), and relief valve (Figure 2, Item 9) from control valve (Figure 2, Item 13). Discard o-ring.
1 14
2 3 12 4 15 5
12
13
12 6 7 8 9 10
M6028DAA
11 12
0721-3
TM 9-2320-272-23-4
0721
INSTALLATION 1. 2. 3. Install six o-rings (Figure 3, Item 12), fittings (Figure 3, Items 1, 4, and 14), and elbows (Figure 3, Items 3 and 11) on control valve (Figure 3, Item 13). Position as noted in removal. Install elbows (Figure 3, Items 2 and 5) and adapter (Figure 3, Item 10) on valve fittings (Figure 3, Items 1 and 4) and elbow (Figure 3, Item 11). Install relief valve (Figure 3, Item 9), spring (Figure 3, Item 8), o-ring (Figure 3, Item 7), and plug (Figure 3, Item 6) in control valve (Figure 3, Item 13).
1 14
2 3 12 4 15 5
12
13
12 6 7 8 9 10
M9945DAA
11 12
Figure 3. Front and Rear Winch Control Valve Installation.
0721-4
TM 9-2320-272-23-4
0721
INSTALLATION - Continued 4. 5. Install bracket (Figure 4, Item 10) on frame (Figure 4, Item 16) with four screws (Figure 4, Item 11) and nuts (Figure 4, Item 9). Install control valve (Figure 4, Item 8) on bracket (Figure 4, Item 10) with three screws (Figure 4, Item 12) and locknuts (Figure 4, Item 13).
WARNING
Do not cross hoses during installation. Failure to comply may result in injury or death to personnel. 6. Install hoses (Figure 4, Items 2, 4, 5, 6, 7, and 17) on control valve (Figure 4, Item 8).
NOTE
Cable clevises are installed the same. 7. Install two cable clevises (Figure 4, Item 1) on control valve (Figure 4, Item 8) rod with clevis pin (Figure 4, Item 3), washer (Figure 4, Item 14), and cotter pin (Figure 4, Item 15). Bend over end of cotter pin.
17 1 2 3 4 5
1 16 15 14 12 13 8 11 10 9
M9946DAA
Figure 4. Front and Rear Winch Control Valve Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Fill hydraulic oil reservoir. (Volume 5, WP 0820) Start engine and check hydraulic pump operation. (TM 9-2320-272-10)
0721-5/6 blank
TM 9-2320-272-23-4
0722
FIELD MAINTENANCE REAR WINCH CABLE TENSIONER REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Caliper Set, Micrometer, Outside (Volume 5, WP 0826, Table 1, Item 11) Press, Arbor, Hand Operated (Volume 5, WP 0826, Table 1, Item 39) Materials/Parts Grease, Automotive and Artillery (Volume 5, WP 0825, Table 1, Item 28) Cotter Pin (Volume 5, WP 0827, Table 1, Item 341) Qty: 4 Cotter Pin (Volume 5, WP 0827, Table 1, Item 380) Qty: 2 Lockwasher (Volume 5, WP 0827, Table 1, Item 405) Qty: 4 Materials/Parts (cont.) Lockwasher (Volume 5, WP 0827, Table 1, Item 437) Qty: 8 Packing with Retainer (Volume 5, WP 0827, Table 1, Item 214) Qty: 4 References TM 9-237 Volume 5, WP 0820 Equipment Condition Rear winch cable removed. (WP 0710)
0722-1
TM 9-2320-272-23-4
0722
DISASSEMBLY 1. 2. 3. 4. 5. Remove four cotter pins (Figure 1, Item 10), pins (Figure 1, Items 9 and 11), and lever (Figure 1, Item 7) from bracket (Figure 1, Item 8). Discard cotter pins. Remove four screws (Figure 1, Item 16) and lockwashers (Figure 1, Item 17) from bracket (Figure 1, Item 15). Discard lockwashers. Remove two nuts (Figure 1, Item 20), lockwashers (Figure 1, Item 19), screws (Figure 1, Item 18), and bracket (Figure 1, Item 15) from tensioner frame (Figure 1, Item 14). Discard lockwashers. Remove two nuts (Figure 1, Item 1), lockwashers (Figure 1, Item 2), screws (Figure 1, Item 6), and tensioner frame (Figure 1, Item 14) from frame bracket (Figure 1, Item 8). Discard lockwashers. Remove four nuts (Figure 1, Item 4), lockwashers (Figure 1, Item 5), screws (Figure 1, Item 13), washers (Figure 1, Item 12), and bracket (Figure 1, Item 8) from rear winch (Figure 1, Item 3). Discard lockwashers.
0722-2
TM 9-2320-272-23-4
0722
1 20
18 17
19
6 16 15 14 10 11 8 10 9
M6034DAA
12 13 7
Figure 1.
Rear Winch Cable Tensioner Disassembly.
0722-3
TM 9-2320-272-23-4
0722
DISASSEMBLY - Continued 6. 7. 8. 9. 10. 11. 12. 13. 14. Remove cotter pin (Figure 2, Item 1) and pin (Figure 2, Item 8) from tensioner frame (Figure 2, Item 2). Discard cotter pin. Remove grease fitting (Figure 2, Item 7) from pin (Figure 2, Item 8). Remove sheave (Figure 2, Item 5), two thrust washers (Figure 2, Item 3), and packings with retainers (Figure 2, Item 4) from tensioner frame (Figure 2, Item 2). Discard packings with retainers. Remove bearing (Figure 2, Item 6) from sheave (Figure 2, Item 5). Remove cotter pin (Figure 2, Item 9) and pin (Figure 2, Item 16) from tensioner frame (Figure 2, Item 2). Discard cotter pin. Remove grease fitting (Figure 2, Item 15) from pin (Figure 2, Item 16). Remove sheave (Figure 2, Item 13), two thrust washers (Figure 2, Item 11), and packings with retainers (Figure 2, Item 12) from frame (Figure 2, Item 2). Discard packings with retainers. Remove bearing (Figure 2, Item 14) from sheave (Figure 2, Item 13). Remove frame (Figure 2, Item 10) from tensioner frame (Figure 2, Item 2).
NOTE
Parts for both sheaves are inspected the same way. 15. 16. 17. Clean and inspect thrust washers (Figure 2, Items 3 and 11) for cracks or wear. Measure thickness with a micrometer and discard thrust washers if thickness is less than 0.055 in. (1.40 mm) or if cracked. Clean and inspect bearings (Figure 2, Items 6 and 14) for chips, cracks, scoring, or damaged cage. Discard if chipped, cracked, scored, or cage is damaged. Clean and inspect pins (Figure 2, Item 8) and (Figure 2, Item 16) for cracks or wear. Measure with a micrometer and discard if outer diameter is less than 1.245 in. (31.63 mm) or if cracked.
NOTE
Refer to TM 9-237 for welding and straightening techniques. 18. 19. Inspect sheave frame (Figure 2, Item 10) for bends and cracks. Repair minor bends or cracks. Clean and inspect tensioner frame (Figure 2, Item 2) for bends, cracks, and broken welds. Repair minor bends, cracks, and broken welds. Replace if not repairable.
0722-4
TM 9-2320-272-23-4
0722
1 2
8 7
4 3 2 4 6 5
16 15 10
11 12 13 11 12 14
M10259DAA
Rear Winch Cable Tensioner Disassembly.
0722-5
TM 9-2320-272-23-4
0722
ASSEMBLY 1. 2. 3. 4. Position sheave frame (Figure 3, Item 3) in tensioner frame (Figure 3, Item 1). Coat bearing (Figure 3, Item 7) with GAA grease and install in sheave (Figure 3, Item 6). Install grease fitting (Figure 3, Item 9) in pin (Figure 3, Item 8). Place steel sides of two packings with retainers (Figure 3, Item 5) on each side of bearing (Figure 3, Item 7) in sheave (Figure 3, Item 6) and place sheave and two thrust washers (Figure 3, Item 4) in frame (Figure 3, Item 3). Install sheave (Figure 3, Item 6) in tensioner frame (Figure 3, Item 1) and frame (Figure 3, Item 3) with pin (Figure 3, Item 8) and cotter pin (Figure 3, Item 2). Coat bearing (Figure 3, Item 14) with GAA grease and install in sheave (Figure 3, Item 13). Install grease fitting (Figure 3, Item 16) in pin (Figure 3, Item 15). Place steel sides of two packings with retainers (Figure 3, Item 12) on each side of bearing (Figure 3, Item 14) in sheave (Figure 3, Item 13) and place sheave and two thrust washers (Figure 3, Item 11) in tensioner frame (Figure 3, Item 1). Install sheave (Figure 3, Item 13) in tensioner frame (Figure 3, Item 1) with pin (Figure 3, Item 15) and cotter pin (Figure 3, Item 10).
5. 6. 7. 8.
9.
0722-6
TM 9-2320-272-23-4
0722
5 6 4 5 7 10
16
15
14 11 12
13
12 11
M6036DAA
Figure 3. Rear Winch Cable Tensioner Assembly.
0722-7
TM 9-2320-272-23-4
0722
ASSEMBLY - Continued 10. 11. 12. 13. 14. Install bracket (Figure 4, Item 8) on rear winch (Figure 4, Item 3) with four washers (Figure 4, Item 11), screws (Figure 4, Item 12), lockwashers (Figure 4, Item 5), and nuts (Figure 4, Item 4). Install tensioner frame (Figure 4, Item 14) on bracket (Figure 4, Item 8) with two screws (Figure 4, Item 6), lockwashers (Figure 4, Item 2), and nuts (Figure 4, Item 1). Install bracket (Figure 4, Item 15) on tensioner frame (Figure 4, Item 14) with two screws (Figure 4, Item 18), lockwashers (Figure 4, Item 19), and nuts (Figure 4, Item 20). Install bracket (Figure 4, Item 15) on rear winch (Figure 4, Item 3) with lockwasher (Figure 4, Item 17) and screw (Figure 4, Item 16). Install lever (Figure 4, Item 7) on bracket (Figure 4, Item 8) and rod of frame (Figure 4, Item 14) with two pins (Figure 4, Items 9 and 13) and four cotter pins (Figure 4, Item 10).
1 20
18 17
19
6 16 15 14 10 13 8 10 9
M6037DAA
11 12 7
Rear Winch Assembly.
0722-8
TM 9-2320-272-23-4
0722
FOLLOW-ON MAINTENANCE 1. 2. Lubricate rear winch tensioner. (Volume 5, WP 0820) Install rear winch cable. (WP 0710)
0722-9/10 blank
TM 9-2320-272-23-4
0723
FIELD MAINTENANCE DUMP ROLLER ARM REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Hammer, Soft Face (Volume 5, WP 0826, Table 1, Item 22) Materials/Parts Grease, Automotive and Artillery (Volume 5, WP 0825, Table 1, Item 28) Equipment Condition Parking brake set. (TM 9-2320-272-10) Dump body removed. (WP 0594)
0723-1
TM 9-2320-272-23-4
0723
REMOVAL
WARNING
NOTE
Left and right roller arms are replaced the same way. Right roller arm shown. Use soft-faced hammer to tap roller arm if necessary to complete Step (1). Remove roller arm (Figure 1, Item 1) from hoist cylinder crosshead shaft (Figure 1, Item 2).
1
M10104DAA
Figure 1. Dump Roller Removal. END OF TASK
0723-2
TM 9-2320-272-23-4
0723
INSTALLATION Install roller arm (Figure 2, Item 1) on hoist cylinder crosshead shaft (Figure 2, Item 2).
1
M4050DAA
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install dump body. (WP 0594) Lubricate roller arms. (TM 9-2320-272-10)
Dump Roller Installation.
0723-3/4 blank
TM 9-2320-272-23-4
0724
FIELD MAINTENANCE DUMP HOIST CYLINDER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Hammer, Soft Face (Volume 5, WP 0826, Table 1, Item 22) Suitable Container Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Cloth, Cleaning (Volume 5, WP 0825, Table 1, Item 19) Materials/Parts (cont.) Hydraulic Fluid (Volume 5, WP 0825, Table 1, Item 35) Lockwasher (Volume 5, WP 0827, Table 1, Item 437) Qty: 12 Equipment Condition Dump body removed. (WP 0594) Dump roller arms removed. (WP 0723)
0724-1
TM 9-2320-272-23-4
0724
REMOVAL
WARNING
NOTE
A 4x4 block of wood is recommended for use as support. 1. 2. Raise hoist cylinders (Figure 1, Items 4 and 10) from subframe (Figure 1, Item 5) and place wood support (Figure 1, Item 3) between subframe (Figure 1, Item 5) and cylinders (Figure 1, Items 4 and 10). Remove four screws (Figure 1, Item 2), lockwashers (Figure 1, Item 1), two upper crosshead retainers (Figure 1, Item 6), lower cross head retainers (Figure 1, Item 8), and crosshead (Figure 1, Item 9) from two piston rods (Figure 1, Item 7). Discard lockwashers.
4 5
6 7 10 9 8
Figure 1. Dump Hoist Cylinder Removal.
M10230DAA
0724-2
TM 9-2320-272-23-4
0724
REMOVAL - Continued
CAUTION
Plug all hydraulic lines or openings to prevent dirt from entering and damaging components
NOTE
Cross fitting to hoist cylinder hoses must be disconnected from cross fittings first. Then hoses can be removed from hoist cylinders. Have drainage containers ready to catch oil. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. Tag all parts for installation. 3. 4. 5. 6. Disconnect hydraulic hoses (Figure 2, Items 4 and 9) from right cross fitting (Figure 2, Item 7). Disconnect hydraulic hoses (Figure 2, Items 5 and 8) from left cross fitting (Figure 2, Item 6). Disconnect hydraulic hoses (Figure 2, Items 4 and 9) from right and left cylinder ports A (Figure 2, Items 2 and 10). Disconnect hydraulic hoses (Figure 2, Items 5 and 8) from right and left cylinder ports B (Figure 2, Items 1 and 3).
10
9 4 8 5 6
M10105DAA
Figure 2.
Dump Hoist Cylinder Removal.
0724-3
TM 9-2320-272-23-4
0724
REMOVAL - Continued 7. Remove eight screws (Figure 3, Item 3), lockwashers (Figure 3, Item 4), four bearing caps (Figure 3, Item 2), and hoist cylinders (Figure 3, Items 1 and 5) from subframe (Figure 3, Item 6). Discard lockwashers.
4 6 5 2
M10228DAA
Figure 3. Dump Hoist Cylinder Removal. END OF TASK
0724-4
TM 9-2320-272-23-4
0724
INSTALLATION 1. 2. Position hoist cylinders (Figure 4, Items 1 and 5) on subframe (Figure 4, Item 7) with bypass tubes (Figure 4, Item 5) facing down. Install each hoist cylinder (Figure 4, Items 1 and 6) with two bearing caps (Figure 4, Item 2), four lockwashers (Figure 4, Item 4), and screws (Figure 4, Item 3).
1 2
4 5 3 2 7 6 5 4
M10229DAA
Figure 4.
Dump Hoist Cylinder Installation.
0724-5
TM 9-2320-272-23-4
0724
NOTE
To properly identify hose connection points, the cylinder port with bypass tube extending to the middle of the cylinder will be identified as port B. The cylinder port with bypass tube extending full length of the cylinder will be identified as port A. 3. 4. Connect hydraulic hoses (Figure 5, Items 4 and 9) to left cylinder port A (Figure 5, Item 2), right cylinder port A (Figure 5, Item 10), and right cross fitting (Figure 5, Item 7). Connect hydraulic hoses (Figure 5, Items 5 and 8) to left cylinder port B (Figure 5, Item 3), right cylinder port B (Figure 5, Item 1) and left cross fitting (Figure 5, Item 6).
10
9 4 8 5 6
M10232DAA
Figure 5. Dump Hoist Cylinder Installation.
0724-6
TM 9-2320-272-23-4
0724
INSTALLATION - Continued 5. Position crosshead (Figure 6, Item 9) on piston rods (Figure 6, Item 7) and install with two upper crosshead retainers (Figure 6, Item 6), lower crosshead retainers (Figure 6, Item 8), four lockwashers (Figure 6, Item 1), and screws (Figure 6, Item 2). Raise hoist cylinders (Figure 6, Items 4 and 10) and remove wood block (Figure 6, Item 3).
6.
4 5
6 7 10 9 8
Figure 6. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install dump roller arms. (WP 0723) Install dump body. (WP 0594) Fill hydraulic reservoir to proper oil level. (Volume 5, WP 0820) Start engine and operate dump through full range. Check for leaks and proper operation. (TM 9-2320-272-10) Dump Hoist Cylinder Installation.
M10231DAA
0724-7/8 blank
TM 9-2320-272-23-4
0725
FIELD MAINTENANCE TRANSFER CASE POWER TAKEOFF (PTO) REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Hammer, Soft Face (Volume 5, WP 0826, Table 1, Item 22) Indicator, Dial (Volume 5, WP 0826, Table 1, Item 25) Press, Arbor, Hand Operated (Volume 5, WP 0826, Table 1, Item 39) Wrench, Torque, Click, Ratcheting, 1/2" Drive, 250 Ft-Lb (Volume 5, WP 0826, Table 1, Item 63) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Cleaning Compound, Solvent (Volume 5, WP 0825, Table 1, Item 16, 17) Cloth, Cleaning (Volume 5, WP 0825, Table 1, Item 19) Sealing Compound (Volume 5, WP 0825, Table 1, Item 56) Tape, Antiseizing (Volume 5, WP 0825, Table 1, Item 65) Cotter Pin (Volume 5, WP 0827, Table 1, Item 336) Qty: 1 Cotter Pin (Volume 5, WP 0827, Table 1, Item 339) Qty: 1 Gasket (Volume 5, WP 0827, Table 1, Item 92) Qty: 1 Materials/Parts (cont.) O-ring (Volume 5, WP 0827, Table 1, Item 299) Qty: 1 Oil Seal (Volume 5, WP 0827, Table 1, Item 40) Qty: 1 Oil Seal (Volume 5, WP 0827, Table 1, Item 252) Qty: 1 Oil Sleeve (Volume 5, WP 0827, Table 1, Item 81) Qty: 1 Snapring (Volume 5, WP 0827, Table 1, Item 51) Qty: 1 Woodruff Key (Volume 5, WP 0827, Table 1, Item 414) Qty: 1 References TM 9-214 TM 9-2320-272-10 Volume 5, WP 0820 Equipment Condition Transfer case PTO-to-hydraulic pump propeller shaft removed. (WP 0713)
0725-1
TM 9-2320-272-23-4
0725
REMOVAL 1. Remove cotter pin (Figure 1, Item 1), washer (Figure 1, Item 2), clevis pin (Figure 1, Item 4), and clevis (Figure 1, Item 3) from transfer case Power Takeoff (PTO) select lever (Figure 1, Item 5). Discard cotter pin.
NOTE
Have drainage container ready to catch oil. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. 2. 3. 4. 5. 6. 7. 8. Disconnect transfer case oil return line (Figure 1, Item 9) from adapter (Figure 1, Item 10) and plug opening of transfer case oil return line. Remove adapter (Figure 1, Item 10) from PTO unit (Figure 1, Item 11). Remove six screws (Figure 1, Item 6) and washers (Figure 1, Item 7) from transfer case (Figure 1, Item 8). Remove PTO unit (Figure 1, Item 11) from transfer case (Figure 1, Item 8). Remove setscrew (Figure 1, Item 12) from PTO oil pump drive gear assembly (Figure 1, Item 15). Slide PTO oil pump drive gear assembly (Figure 1, Item 15) off transfer case main input shaft (Figure 1, Item 13). Remove oil seal (Figure 1, Item 14) from PTO oil pump drive gear assembly (Figure 1, Item 15). Discard oil seal.
0725-2
TM 9-2320-272-23-4
0725
REMOVAL - Continued
1 2
3 4
7 6 12 8
9 13 14 15
10 10 11
11 9
M6098DAA
Transfer Case PTO Removal.
0725-3
TM 9-2320-272-23-4
0725
DISASSEMBLY 1. 2. 3. Remove oil line (Figure 2, Item 2) and adapter elbows (Figure 2, Items 1 and 15) from oil pump housing (Figure 2, Item 3) and bearing cap (Figure 2, Item 12). Remove two nuts (Figure 2, Item 8), washers (Figure 2, Item 5), screws (Figure 2, Item 4), washers (Figure 2, Item 5), and PTO housing (Figure 2, Item 7) from oil pump adapter (Figure 2, Item 6). Remove four screws (Figure 2, Item 14) and washers (Figure 2, Item 13) from bearing cap (Figure 2, Item 12) and PTO housing (Figure 2, Item 7).
NOTE
Tag shims for installation. 4. Remove bearing cap (Figure 2, Item 12), shims (Figure 2, Item 11), outer bearing race (Figure 2, Item 10), and PTO shaft (Figure 2, Item 9) from PTO housing (Figure 2, Item 7).
0725-4
TM 9-2320-272-23-4
0725
1 7 2 3 15 4 5 6 5 8
12
14
13
12
11
Figure 2.
10
PTO Shaft Disassembly.
M6099DAA
0725-5
TM 9-2320-272-23-4
0725
DISASSEMBLY - Continued 5. 6. 7. Remove cotter pin (Figure 3, Item 7) and washer (Figure 3, Item 6) from PTO shift lever (Figure 3, Item 5) and shifter shaft (Figure 3, Item 10). Discard cotter pin. Remove screw (Figure 3, Item 8), washer (Figure 3, Item 9), and PTO shift lever (Figure 3, Item 5) from PTO housing (Figure 3, Item 1). Remove four screws (Figure 3, Item 4), washers (Figure 3, Item 3), and plate (Figure 3, Item 2) from PTO housing (Figure 3, Item 1).
2 3 4 10
9 8
6 5
7
M6100DAA
Figure 3. PTO Shift Lever Disassembly.
0725-6
TM 9-2320-272-23-4
0725
DISASSEMBLY - Continued 8. 9. 10. Tilt PTO housing (Figure 4, Item 1) until dowel (Figure 4, Item 6), spring (Figure 4, Item 7), and detent ball (Figure 4, Item 8) fall out. Remove setscrew (Figure 4, Item 5) and shifter shaft (Figure 4, Item 3) from shifter fork (Figure 4, Item 4). Remove o-ring (Figure 4, Item 2) from shifter shaft (Figure 4, Item 3). Discard o-ring.
NOTE
Mark position of shifter fork for installation. 11. 12. Remove shifter fork (Figure 4, Item 4) from PTO housing (Figure 4, Item 1). Tilt PTO housing (Figure 4, Item 1) until clutch collar (Figure 4, Item 9) falls out.
1
3 4 5 7 6
8 9
1 9
M6101DAA
Figure 4.
PTO Clutch Collar Disassembly.
0725-7
TM 9-2320-272-23-4
0725
DISASSEMBLY - Continued 13. Remove inner bearing race (Figure 5, Item 2) from PTO housing (Figure 5, Item 1).
M10196DAA
Figure 5. 14. 15. 16. 17.
PTO Disassembly.
Remove access plug (Figure 6, Item 7) and gasket (Figure 6, Item 8) from oil pump adapter (Figure 6, Item 1). Discard gasket. Remove outer snapring (Figure 6, Item 9) from pump shaft (Figure 6, Item 5). Discard snapring. Remove three screws (Figure 6, Item 4), oil pump adapter (Figure 6, Item 1), and drive gear (Figure 6, Item 6) from oil pump (Figure 6, Item 3). Remove woodruff key (Figure 6, Item 2) from oil pump shaft (Figure 6, Item 5). Discard woodruff key.
0725-8
TM 9-2320-272-23-4
0725
3 4
9 8 7 6 5
M10197DAA
Figure 6. 18. 19.
PTO Disassembly.
Remove outer (Figure 7, Item 3) and inner (Figure 7, Item 2) output shaft bearings from PTO shaft (Figure 7, Item 1). Remove oil seal sleeve (Figure 7, Item 4) from PTO shaft (Figure 7, Item 1). Discard oil sleeve.
2
4 3
M10195DAA
Figure 7.
PTO Disassembly.
0725-9
TM 9-2320-272-23-4
0725
DISASSEMBLY - Continued 20. Remove PTO oil seal (Figure 8, Item 2) from bearing cap (Figure 8, Item 1). Discard PTO oil seal.
2
Figure 8. END OF TASK CLEANING AND INSPECTION
M6102DAA
PTO Disassembly.
WARNING
Solvent cleaning compound is flammable and toxic. Do not use near an open flame and always have a fire extinguisher nearby when solvents are used. Use only in well-ventilated places, wear protective clothing, and dispose of cleaning rags in approved container. Failure to comply may result in damage to equipment, injury, or death to personnel.
CAUTION
Cleaning and inspection instructions include PTO oil pump drive gear and collar assembly removed from transfer case input shaft. 1. 2. 3. Clean all transfer case PTO components with solvent cleaning compound and dry with cleaning cloth. Inspect PTO shaft (Figure 9, Item 1) for pitting, galling, and scoring. If pitted, galled, or scored, replace PTO shaft (Figure 9, Item 1). Inspect inner (Figure 9, Item 2) and outer (Figure 9, Item 5) shaft bearings and two bearing races (Figure 9, Items 3 and 4) for cracking, pitting, scoring, and discoloration. If any matched bearings (Figure 9, Item 2 or 5) or races (Figure 9, Item 3 or 4) are pitted, cracked, scored, or discolored, discard and replace all four (TM 9-214).
0725-10
TM 9-2320-272-23-4
0725
3 2 1 5 4
M10199DAA
Figure 9. 4. 5.
PTO Cleaning and Inspection.
Inspect PTO oil pump drive gear (Figure 10, Item 3) and collar (Figure 10, Item 1) for cracks, pitting, scoring, or missing teeth. If cracked, pitted, scored, or teeth are missing, replace PTO oil pump drive gear and collar. Inspect bearing cap (Figure 10, Item 2) for cracks. If cracked, replace bearing cap.
2 3 1
M10200DAA
Figure 10.
0725-11
TM 9-2320-272-23-4
0725
CLEANING AND INSPECTION - Continued 6. 7. Inspect oil pump adapter (Figure 11, Item 3) for cracks. If cracked, replace pump adapter. Inspect oil pump (Figure 11, Item 2) and shaft (Figure 11, Item 1) for cracks and scoring. If cracked or scored, replace oil pump and shaft.
2
3 1
M10201DAA
Figure 11. 8.
Inspect PTO housing (Figure 12, Item 1) for cracks, or pitting in bores and on machined surfaces. If PTO housing is cracked or pitted in bores or on machined surfaces, replace transfer case PTO.
1
M6103DAA
0725-12
TM 9-2320-272-23-4
0725
ASSEMBLY 1. 2. Install woodruff key (Figure 13, Item 3) on oil pump shaft (Figure 13, Item 6). Position oil pump adapter (Figure 13, Item 1) against oil pump (Figure 13, Item 4), align oil pump gear (Figure 13, Item 2) on oil pump shaft (Figure 13, Item 6), and install three screws (Figure 13, Item 5). Tighten screws 9 to 11 lb-ft (12 to 15 Nm). Install snapring (Figure 13, Item 9) on oil pump shaft (Figure 13, Item 6). Install adapter plug gasket (Figure 13, Item 8) and adapter plug (Figure 13, Item 7) on oil pump adapter (Figure 13, Item 1). Tighten adapter plug 80 lb-ft (108 Nm).
3. 4.
4 5
3 2
9 8 7 6
M6104DAA
Figure 13.
Transfer Case PTO Assembly.
0725-13
TM 9-2320-272-23-4
0725
ASSEMBLY - Continued 5. 6. 7. Install inner bearing (Figure 14, Item 2), outer bearing (Figure 14, Item 8), and oil seal sleeve (Figure 14, Item 9) on PTO shaft (Figure 14, Item 1) with arbor press and mandrel. Position inner bearing race (Figure 14, Item 3) over inner bearing (Figure 14, Item 2) on PTO shaft (Figure 14, Item 1). Position PTO shaft (Figure 14, Item 1) in PTO housing (Figure 14, Item 6) through bearing cap end (Figure 14, Item 5) of PTO housing. Ensure inner bearing race (Figure 14, Item 3) seats squarely in bore of PTO housing on shoulder (Figure 14, Item 4). Position outer bearing race (Figure 14, Item 7) in PTO housing (Figure 14, Item 6). Ensure outer bearing race seats squarely in bore of PTO housing.
8.
5 4
Figure 14. Transfer Case PTO Assembly.
M10202DAA
NOTE
Ensure OUTSIDE stamping is up. 9. Using arbor press and mandrel (Figure 15, Item 3), install oil seal (Figure 15, Item 1) in bearing cap (Figure 15, Item 2).
0725-14
TM 9-2320-272-23-4
0725
3
M10203DAA
Figure 15.
NOTE
Steps (10) and (11) establish starting shim pack thickness. 10. 11. 12. Install bearing cap (Figure 16, Item 5) on transfer case PTO (Figure 16, Item 2) and tap alternately around outer edge with soft-faced hammer. Using feeler gauge, measure clearance between cap (Figure 16, Item 5) and transfer case PTO (Figure 16, Item 2). Record measurement. Remove bearing cap (Figure 16, Item 5) from transfer case PTO (Figure 16, Item 2).
CAUTION
Do not apply sealer on mating surfaces.
NOTE
Use measurement obtained in Step (11) add a 0.003 in. (0.0762 mm) shim for starting shim pack thickness. 13. Install starting shim pack (Figure 16, Item 1) and bearing cap (Figure 16, Item 5) on transfer case PTO (Figure 16, Item 2) with four washers (Figure 16, Item 4) and screws (Figure 16, Item 3). Tighten screws 18 to 24 lb-ft (24 to 32 Nm). Position dial indicator (Figure 16, Item 7) plunger (Figure 16, Item 8) against PTO shaft (Figure 16, Item 6).
14.
0725-15
TM 9-2320-272-23-4
0725
NOTE
Steps (15) through (17) check transfer PTO shaft end play. 15. 16. 17. 18. Force transfer PTO shaft (Figure 16, Item 6) to rear of transfer case PTO (Figure 16, Item 2). Set dial indicator to zero. Force transfer PTO shaft (Figure 16, Item 6) to front of transfer case PTO (Figure 16, Item 2) and record reading shown on dial indicator. End play should be 0.001 to 0.005 in. (0.0254 to 0.127 mm). Remove four screws (Figure 16, Item 3), washers (Figure 16, Item 4), and bearing cap (Figure 16, Item 5) from transfer case PTO (Figure 16, Item 2).
CAUTION
Do not apply sealer to mating surfaces.
NOTE
Use reading obtained in Step (17) plus a 0.003 in. (0.0762 mm) shim for starting shim pack thickness. 19. Install starting shim pack (Figure 16, Item 1) and bearing cap (Figure 16, Item 5) on transfer case PTO (Figure 16, Item 2) with four washers (Figure 16, Item 4) and screws (Figure 16, Item 3). Tighten screws 18 to 24 lb-ft (24 to 32 Nm). Position dial indicator plunger against PTO shaft (Figure 16, Item 6).
20.
NOTE
Steps (21) through (23) check transfer PTO shaft end play. 21. 22. 23. 24. Force transfer PTO shaft (Figure 16, Item 6) to rear of transfer case PTO (Figure 16, Item 2). Set dial indicator to zero and force transfer PTO shaft (Figure 16, Item 6) to front of transfer case PTO (Figure 16, item 2). Record reading shown on dial indicator. End play should be 0.001 to 0.005 in. (0.0254 to 0.127 mm). Remove four screws (Figure 16, Item 3), washers (Figure 16, Item 4), and bearing cap (Figure 16, Item 5) from transfer case PTO (Figure 16, Item 2).
NOTE
Use reading obtained in Step (23) for number or thickness of shims to be removed or added for transfer case PTO shaft adjustment. 25. 26. Remove or add shims (Figure 16, Item 1) as necessary. Remove shim pack (Figure 16, Item 1).
NOTE
Do not apply sealer to shims. 27. 28. Apply a light coat of sealer to mating surfaces or transfer case PTO (Figure 16, Item 2) and bearing cap (Figure 16, Item 5). Install shim pack (Figure 16, Item 1) and bearing cap (Figure 16, Item 5) on transfer case PTO (Figure 16, Item 2) with four washers (Figure 16, Item 4) and screws (Figure 16, Item 3). Tighten screws 18 to 24 lb-ft (24 to 32 Nm).
0725-16
TM 9-2320-272-23-4
0725
6 8
M6105DAA
Figure 16.
0725-17
TM 9-2320-272-23-4
0725
CAUTION
Clutch collar and shifter must be properly installed to ensure proper PTO operation. Ensure clutch collar internal splines face away from PTO mounting flange and thick edge of shifter fork faces shifter shaft. 29. 30. 31. 32. Position splined end (Figure 17, Item 19) of clutch collar (Figure 17, Item 13) over PTO shaft (Figure 17, Item 18). Position finger ends (Figure 17, Item 5) of shifter fork (Figure 17, Item 6) in center groove (Figure 17, Item 12) of clutch collar (Figure 17, Item 13). Install o-ring (Figure 17, Item 2) on shifter shaft (Figure 17, Item 4). Place shift shaft (Figure 17, Item 4) through PTO housing bore (Figure 17, Item 11) and fork (Figure 17, Item 6) and install with setscrew (Figure 17, Item 7) into hole (Figure 17, Item 3). Tighten setscrew 7 to 9 lb-ft (10 to 12 Nm). Place detent ball (Figure 17, Item 10), spring (Figure 17, Item 9), and dowel (Figure 17, Item 8) into PTO housing bore (Figure 17, Item 1). Install cover plate (Figure 17, Item 15) on PTO housing (Figure 17, Item 14) with four washers (Figure 17, Item 16) and screws (Figure 17, Item 17). Tighten screws 18 to 24 lb-ft (24 to 32 Nm).
33. 34.
0725-18
TM 9-2320-272-23-4
0725
1
2 3 4 5 6 10 13 13 19 12 11 5 9 8 7
14 15
18
16 17
M6106DAA
Figure 17.
0725-19
TM 9-2320-272-23-4
0725
NOTE
At this point, check operation of PTO shifter shaft. Shifter shaft must be able to be moved into two positions. 35. 36. Install PTO shift lever (Figure 18, Item 2) on shifter shaft (Figure 18, Item 3) with washer (Figure 18, Item 4) and cotter pin (Figure 18, Item 5). Install PTO shift lever (Figure 18, Item 2) on PTO housing end (Figure 18, Item 1) with washer (Figure 18, Item 7) and screw (Figure 18, Item 6).
3 2 4 7 6 5
M10256DAA
Figure 18. Transfer Case PTO Assembly.
0725-20
TM 9-2320-272-23-4
0725
ASSEMBLY - Continued 37. Install oil pump adapter (Figure 19, Item 5) on PTO housing (Figure 19, Item 1) with four washers (Figure 19, Item 2), two screws (Figure 19, Item 4), and nuts (Figure 19, Item 3). Tighten screws 15 to 20 lb-ft (20 to 27 Nm).
1 2 3
M10257DAA
Figure 19. 38. 39.
Install adapter elbows (Figure 20, Items 1 and 4) on PTO housing (Figure 20, Item 3). Install oil line (Figure 20, Item 2) on PTO adapter elbows (Figure 20, Items 1 and 4).
1 2
M6106-1DAA
0725-21
TM 9-2320-272-23-4
0725
INSTALLATION 1. 2. Install oil seal (Figure 21, Item 3) on PTO oil pump drive gear assembly (Figure 21, Item 4). Install PTO oil pump drive gear assembly (Figure 21, Item 4) on transfer case main input shaft (Figure 21, Item 2). Align setscrew (Figure 21, Item 1) hole in gear assembly (Figure 21, Item 4) with recess in main input shaft. Install setscrew (Figure 21, Item 1) in PTO oil pump drive gear assembly (Figure 21, Item 4) and apply sealing compound to threads of setscrew. Tighten setscrew 84 to 108 lb-in. (10 to 12 Nm). Install PTO (Figure 21, Item 10) on transfer case (Figure 21, Item 7) with six washers (Figure 21, Item 6) and screws (Figure 21, Item 5). Tighten screws 40 to 65 lb-ft (54 to 88 Nm).
3. 4.
NOTE
Wrap male pipe threads with antiseize tape prior to installation. 5. 6. 7. Install adapter (Figure 21, Item 9) on PTO (Figure 21, Item 10). Connect transfer case oil return line (Figure 21, Item 8) to adapter (Figure 21, Item 9). Install PTO clevis (Figure 21, Item 13) on PTO select lever (Figure 21, Item 15) with clevis pin (Figure 21, Item 14), washer (Figure 21, Item 12), and cotter pin (Figure 21, Item 11).
0725-22
TM 9-2320-272-23-4
0725
1 6 5
7 2 3 4 9 9 10 8
10 8
11 12
13 14
15
M6107DAA
Transfer Case PTO Installation.
0725-23
TM 9-2320-272-23-4
0725
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Adjust transfer case PTO cable. (WP 0726) Install transfer case PTO-to-hydraulic pump propeller shaft. (WP 0713) Fill transfer case to proper oil level. (Volume 5, WP 0820) Check transfer case PTO for proper operation. (TM 9-2320-272-10)
0725-24
TM 9-2320-272-23-4
0726
FIELD MAINTENANCE TRANSFER CASE POWER TAKEOFF (PTO) CONTROL CABLE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin (Volume 5, WP 0827, Table 1, Item 336) Qty: 1 Locknut (Volume 5, WP 0827, Table 1, Item 282) Qty: 2 Locknut (Volume 5, WP 0827, Table 1, Item 283) Qty: 1 Materials/Parts (cont.) Locknut (Volume 5, WP 0827, Table 1, Item 285) Qty: 2 Tiedown Strap (Volume 5, WP 0827, Table 1, Item 45) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0726-1
TM 9-2320-272-23-4
0726
REMOVAL 1. 2. 3. 4. Remove tiedown straps from Power Takeoff (PTO) cable (Figure 1, Item 10) as required. Discard tiedown straps. Remove cotter pin (Figure 1, Item 6), clevis pin (Figure 1, Item 8), and PTO cable clevis (Figure 1, Item 9) from PTO select lever (Figure 1, Item 7). Discard cotter pin. Remove two locknuts (Figure 1, Item 5), screws (Figure 1, Item 2), clamp (Figure 1, Item 1), PTO cable (Figure 1, Item 10), and shim (Figure 1, Item 3) from PTO cable bracket (Figure 1, Item 4). Discard locknuts. Remove PTO clevis (Figure 1, Item 9) from PTO cable (Figure 1, Item 10).
10
M9786DAA
Figure 1.
Transfer Case PTO Control Cable Removal.
0726-2
TM 9-2320-272-23-4
0726
REMOVAL - Continued 5. 6. 7. Remove two locknuts (Figure 2, Item 6), screws (Figure 2, Item 2), clamp (Figure 2, Item 7), PTO cable (Figure 2, Item 5), and shim (Figure 2, Item 4) from PTO cable bracket (Figure 2, Item 3). Discard locknuts. Remove locknut (Figure 2, Item 1) and PTO cable swivel bolt (Figure 2, Item 9) from select lever (Figure 2, Item 10). Discard locknut. Remove swivel bolt (Figure 2, Item 9) and cable clevis (Figure 2, Item 8) from PTO cable (Figure 2, Item 5).
1 2
3 4
5 10 9 8 7
M6094DAA
Transfer Case PTO Control Cable Removal.
0726-3
TM 9-2320-272-23-4
0726
INSTALLATION 1. 2. 3. 4. 5. Install swivel bolt (Figure 3, Item 9) and cable end (Figure 3, Item 8) on PTO cable (Figure 3, Item 5). Install PTO cable swivel bolt (Figure 3, Item 9) on select lever (Figure 3, Item 10) with locknut (Figure 3, Item 1). Install shim (Figure 3, Item 4), PTO cable (Figure 4, Item 5), and clamp (Figure 3, Item 7) on PTO cable bracket (Figure 3, Item 3) with two screws (Figure 3, Item 2) and locknuts (Figure 3, Item 6). Install PTO clevis (Figure 4, Item 9) on PTO cable (Figure 4, Item 10). Install shim (Figure 3, Item 4), PTO cable (Figure 3, Item 5), and clamp (Figure 3, Item 7) on PTO cable bracket (Figure 3, Item 5) with two screws (Figure 3, Item 2) and locknuts (Figure 3, Item 6).
NOTE
Transfer case PTO cable can be adjusted at two points. Adjustments can be made at transfer case select lever cable clevis or transfer case PTO select lever cable collar. 6. Adjust PTO cable swivel bolt (Figure 4, Item 9) forward until aligned with transfer PTO select lever (Figure 4, Item 7). If necessary, reposition transfer PTO cable (Figure 4, Item 10) at PTO cable collar at crossshaft end of cable (Figure 4, Item 4).
1
2 3 4
5 10 9 8 7
M6095DAA
Figure 3.
Transfer Case PTO Control Cable Installation.
0726-4
TM 9-2320-272-23-4
0726
INSTALLATION - Continued 7. 8. Install PTO clevis (Figure 4, Item 9) on PTO select lever (Figure 4, Item 7) with clevis pin (Figure 4, Item 8) and cotter pin (Figure 4, Item 6). Install tiedown straps on PTO cable (Figure 4, Item 10) as required.
10
M9787DAA
Transfer Case PTO Control Cable Installation.
Check transfer case PTO for proper operation. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0726-5/6 blank
TM 9-2320-272-23-4
0727
FIELD MAINTENANCE TRANSFER CASE POWER TAKEOFF (PTO) CROSS SHAFT (CONTROL LEVER) REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Grease, Automotive and Artillery (Volume 5, WP 0825, Table 1, Item 28) Cotter Pin (Volume 5, WP 0827, Table 1, Item 336) Qty: 1 Locknut (Volume 5, WP 0827, Table 1, Item 256) Qty: 6 Locknut (Volume 5, WP 0827, Table 1, Item 282) Qty: 2 Locknut (Volume 5, WP 0827, Table 1, Item 283) Qty: 1 Locknut (Volume 5, WP 0827, Table 1, Item 285) Qty: 5 Materials/Parts (cont.) Locknut (Volume 5, WP 0827, Table 1, Item 289) Qty: 1 Woodruff Key (Volume 5, WP 0827, Table 1, Item 415) Qty: 1 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Driver's seat removed. (WP 0582)
0727-1
TM 9-2320-272-23-4
0727
REMOVAL 1. 2. Remove locknut (Figure 1, Item 17) and PTO cable swivel bolt (Figure 1, Item 18) from cross shaft lever (Figure 1, Item 30). Discard locknut. Remove two locknuts (Figure 1, Item 16), screws (Figure 1, Item 13), clamp (Figure 1, Item 19), PTO control cable (Figure 1, Item 20), and shim (Figure 1, Item 15) from bracket (Figure 1, Item 14). Discard locknuts.
NOTE
Assistant will help with Step (3). 3. 4. 5. 6. Remove four locknuts (Figure 1, Item 12), screws (Figure 1, Item 1), two cross shaft retaining clamps (Figure 1, Item 3), and shims (Figure 1, Item 4) from cab floor (Figure 1, Item 23). Discard locknuts. Remove grease fittings (Figure 1, Item 2) from cross shaft retaining clamps (Figure 1, Item 3). Remove cotter pin (Figure 1, Item 26), washer (Figure 1, Item 28), and brake lock control valve rod (Figure 1, Item 21) from cross shaft lever (Figure 1, Item 30). Discard cotter pin. Remove locknut (Figure 1, Item 31) and screw (Figure 1, Item 29) from cross shaft lever (Figure 1, Item 30). Discard locknut.
NOTE
Assistant will help with Step (7). 7. Remove six locknuts (Figure 1, Item 22), screws (Figure 1, Item 27), ring seal (Figure 1, Item 25), rubber seal (Figure 1, Item 24), and cross shaft lever (Figure 1, Item 30) from cab floor (Figure 1, Item 23) and cross shaft (Figure 1, Item 5). Discard locknuts. Remove woodruff key (Figure 1, Item 11) and two cross shaft retaining clamps (Figure 1, Item 3) from cross shaft (Figure 1, Item 5). Discard woodruff key. Remove locknut (Figure 1, Item 7), washer (Figure 1, Item 8), helical spring (Figure 1, Item 9), and PTO lever pin (Figure 1, Item 10) from PTO lever (Figure 1, Item 6). Discard locknut.
8. 9.
0727-2
TM 9-2320-272-23-4
0727
REMOVAL - Continued
29
30
31
28 27 26 25 24 23 22 12 20 19 16 18 17 21
3 4 13 2 3 14 4 6 7 5 15 11 9 10 8 1
12
M6096DAA
Figure 1. Transfer Case PTO Cross Shaft (Control Lever) Removal. END OF TASK
0727-3
TM 9-2320-272-23-4
0727
INSTALLATION 1. 2. 3. 4. 5. Install PTO lever pin (Figure 2, Item 10), helical spring (Figure 2, Item 9), and washer (Figure 2, Item 8) on PTO lever (Figure 2, Item 6) with locknut (Figure 2, Item 7). Install two cross shaft retaining clamps (Figure 2, Item 3) on cross shaft (Figure 2, Item 5). Install grease fittings (Figure 2, Item 2) on two cross shaft retaining clamps (Figure 2, Item 3). Apply a small amount of automotive and artillery grease to rounded edge of woodruff key (Figure 2, Item 11) and install on cross shaft (Figure 2, Item 5). Grease will hold woodruff key (Figure 2, Item 7) in place. Insert cross shaft (Figure 2, Item 5) into cross shaft lever (Figure 2, Item 30) and install with screw (Figure 2, Item 29) and locknut (Figure 2, Item 31).
NOTE
Assistant will help with Steps (6) through (8). 6. 7. 8. 9. 10. 11. Install rubber seal (Figure 2, Item 24) and ring seal (Figure 2, Item 25) on cab floor (Figure 2, Item 23) with six screws (Figure 2, Item 27) and locknuts (Figure 2, Item 22). Position cross shaft (Figure 2, Item 5), cross shaft lever (Figure 2, Item 30), and cross shaft retaining clamps (Figure 2, Item 3) on cab floor (Figure 2, Item 23). Install two shims (Figure 2, Item 4) and cross shaft retaining clamps (Figure 2, Item 3) on cab floor (Figure 2, Item 23) with four screws (Figure 2, Item 1) and locknuts (Figure 2, Item 12). Install brake lock control valve rod (Figure 2, Item 21) on cross shaft lever (Figure 2, Item 30) with washer (Figure 2, Item 28) and cotter pin (Figure 2, Item 26). Install PTO cable swivel bolt (Figure 2, Item 18) on cross shaft lever (Figure 2, Item 30) with locknut (Figure 2, Item 17). Install shim (Figure 2, Item 15) and PTO control cable (Figure 2, Item 20) on bracket (Figure 2, Item 14) with clamp (Figure 2, Item 19), two screws (Figure 2, Item 13), and locknuts (Figure 2, Item 16).
0727-4
TM 9-2320-272-23-4
0727
29
30
31
28 27 26 25 24 23 22 12 20 19 16 18 17 21
3 4 13 2 3 14 4 6 7 5 15 11 9 10 8 1
12
M6097DAA
Figure 2. Transfer Case PTO Cross Shaft (Control Lever) Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install driver's seat. (WP 0582) Check transfer case PTO for proper operation. (TM 9-2320-272-10)
0727-5/6 blank
TM 9-2320-272-23-4
0728
FIELD MAINTENANCE TRANSMISSION POWER TAKEOFF (PTO) REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Lubricating Oil (Volume 5, WP 0825, Table 1, Item 44, 45, 46, 47) Tape, Antiseizing (Volume 5, WP 0825, Table 1, Item 65) Cotter Pin (Volume 5, WP 0827, Table 1, Item 333) Qty: 1 Materials/Parts (cont.) Gasket (Volume 5, WP 0827, Table 1, Item 121) Qty: 1 Locknut (Volume 5, WP 0827, Table 1, Item 277) Qty: 1 References Volume 5, WP 0820 Equipment Condition Parking brake set. (TM 9-2320-272-10) Transmission PTO-to-hydraulic pump propeller shaft removed. (WP 0713) Transmission oil dipstick tube removed. (Volume 2, WP 0228)
0728-1
TM 9-2320-272-23-4
0728
REMOVAL 1. 2. 3. 4. 5. 6. Open transmission dipstick access door (Figure 1, Item 1) on inside of cab. Remove two nuts (Figure 1, Item 3), screws (Figure 1, Item 8), clamp (Figure 1, Item 7), and spacer (Figure 1, Item 5) from PTO cable bracket (Figure 1, Item 4). Remove cotter pin (Figure 1, Item 12) and washer (Figure 1, Item 11) from PTO cable pin (Figure 1, Item 9), and lift PTO cable pin away from select lever (Figure 1, Item 10). Discard cotter pin. Tie PTO cable (Figure 1, Item 4) clear of work area. Remove screw (Figure 1, Item 16), washer (Figure 1, Item 15), and bracket (Figure 1, Item 4) from PTO (Figure 1, Item 19). Remove screw (Figure 1, Item 17), washer (Figure 1, Item 18), two screws (Figure 1, Item 14), and washers (Figure 1, Item 13) from PTO (Figure 1, Item 19) and transmission (Figure 1, Item 2).
0728-2
TM 9-2320-272-23-4
0728
REMOVAL - Continued
3 12 19 11 5 10 18 9 7 8
Figure 1.
13 14
6 17 16
Transmission PTO Removal.
4 15
M6112DAA
0728-3
TM 9-2320-272-23-4
0728
REMOVAL - Continued 7. 8. 9. 10. 11. 12. 13. Disconnect oil hose (Figure 2, Item 8) from PTO oil hose adapter (Figure 2, Item 7) and position oil hose clear of work area. Plug end of oil hose (Figure 2, Item 8). Remove two nuts (Figure 2, Item 5), washers (Figure 2, Item 6), screw (Figure 2, Item 3), and washer (Figure 2, Item 4) from PTO (Figure 2, Item 2) and transmission (Figure 2, Item 1). Remove locknut (Figure 2, Item 12) and screw (Figure 2, Item 10) from right frame rail (Figure 2, Item 13) and bracket (Figure 2, Item 11). Discard locknut. Remove PTO (Figure 2, Item 2) and gasket (Figure 2, Item 9) from transmission (Figure 2, Item 1). Discard gasket. Clean gasket remains from mating surfaces of transmission (Figure 2, Item 11) and PTO (Figure 2, Item 2). Remove PTO oil hose adapter (Figure 2, Item 7) from PTO (Figure 2, Item 2) and plug orifice of PTO.
0728-4
TM 9-2320-272-23-4
0728
REMOVAL - Continued
13
1 12 2 11 10
3 9 7 5 4
M6113DAA
Transmission PTO Removal.
0728-5
TM 9-2320-272-23-4
0728
INSTALLATION
NOTE
Wrap male pipe threads with antiseize tape before installation. Remove plug from PTO (if present) before installing PTO oil hose adapter. 1. 2. 3. 4. 5. 6. Install PTO oil hose adapter (Figure 3, Item 7) on PTO (Figure 3, Item 2). Loosely install washer (Figure 3, Item 4) and screw (Figure 3, Item 3) in PTO (Figure 3, Item 2). Install gasket (Figure 3, Item 9) and PTO (Figure 3, Item 2) on transmission (Figure 3, Item 1) with two washers (Figure 3, Item 6) and nuts (Figure 3, Item 5). Tighten screw (Figure 3, Item 3) and nut (Figure 3, Item 5). Remove plug from PTO oil hose (Figure 3, Item 8) and connect PTO oil hose to adapter (Figure 3, Item 7). Install screw (Figure 3, Item 10) and locknut (Figure 3, Item 12) on frame rail (Figure 3, Item 13) and bracket (Figure 3, Item 11).
0728-6
TM 9-2320-272-23-4
0728
13
1 12 2 11 10
3 9 7 5 4
M6114DAA
Figure 3.
Transmission PTO Installation.
0728-7
TM 9-2320-272-23-4
0728
INSTALLATION - Continued 7. 8. 9. 10. Install two washers (Figure 4, Item 3), screw (Figure 4, Item 4), washer (Figure 4, Item 9), and screw (Figure 4, Item 8) on PTO (Figure 4, Item 10) and transmission (Figure 4, Item 2). Install PTO cable bracket (Figure 4, Item 5) on PTO (Figure 4, Item 10) with washer (Figure 4, Item 6) and screw (Figure 4, Item 7). Install PTO cable (Figure 4, Item 16) and PTO cable pin (Figure 4, Item 17) on PTO select lever (Figure 4, Item 18) with washer (Figure 4, Item 19) and cotter pin (Figure 4, Item 20). Install spacer (Figure 4, Item 13) and clamp (Figure 4, Item 15) on PTO cable bracket (Figure 4, Item 5) with two screws (Figure 4, Item 15) and nuts (Figure 4, Item 12).
0728-8
TM 9-2320-272-23-4
0728
12 20 10 3 4 19 13 18 9 5 8 7
Figure 4. END OF TASK Transmission PTO Installation.
17 16 15 14
M6115DAA
0728-9
TM 9-2320-272-23-4
0728
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install transmission PTO-to-hydraulic pump propeller shaft. (WP 0713) Install transmission oil dipstick tube. (Volume 2, WP 0228) Fill transmission to proper oil level. (Volume 5, WP 0820) Start engine, check for leaks, and proper operation of transmission PTO. (TM 9-2320-272-10)
0728-10
TM 9-2320-272-23-4
0729
FIELD MAINTENANCE TRANSMISSION POWER TAKEOFF (PTO) CONTROL CABLE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin (Volume 5, WP 0827, Table 1, Item 331) Qty: 1 Materials/Parts (cont.) Cotter Pin (Volume 5, WP 0827, Table 1, Item 333) Qty: 1 Locknut (Volume 5, WP 0827, Table 1, Item 256) Qty: 4 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0729-1
TM 9-2320-272-23-4
0729
REMOVAL 1. 2. 3. 4. Open transmission dipstick access door (Figure 1, Item 1) inside of cab. Remove two locknuts (Figure 1, Item 2), screws (Figure 1, Item 5), clamp (Figure 1, Item 6), and spacer plate (Figure 1, Item 4) from PTO cable bracket (Figure 1, Item 3). Discard locknuts. Remove cotter pin (Figure 1, Item 11) and washer (Figure 1, Item 10) and lift PTO cable pin (Figure 1, Item 8) free of select lever (Figure 1, Item 9). Discard cotter pin. Remove PTO cable pin (Figure 1, Item 8) from PTO cable (Figure 1, Item 7).
1 2 11
10 9 3 4
5
M6108DAA
Figure 1. Transmission Control Cable Removal.
0729-2
TM 9-2320-272-23-4
0729
REMOVAL - Continued
NOTE
Tag all ends of PTO cable for installation. 5. 6. 7. Remove six screws (Figure 2, Item 9) and access cover (Figure 2, Item 8) from PTO control panel (Figure 2, Item 15). Remove two locknuts (Figure 2, Item 7), screws (Figure 2, Item 2), clamp (Figure 2, Item 6), and spacer (Figure 2, Item 5) from PTO control panel (Figure 2, Item 15). Discard locknuts. Remove cotter pin (Figure 2, Item 11), washer (Figure 2, Item 12), and clevis pin (Figure 2, Item 14) from PTO control lever (Figure 2, Item 1), and pull end of control cable (Figure 2, Item 4) clear of PTO control panel (Figure 2, Item 15). Discard cotter pin. Loosen nut (Figure 2, Item 10) on PTO control cable (Figure 2, Item 4) and remove cable clevis (Figure 2, Item 13). Pull PTO control cable (Figure 2, Item 4) on PTO control panel (Figure 2, Item 15) through grommet (Figure 2, Item 3) and into cab.
1 15 2
8. 9.
14 13 12 11
10 4 5 6 8 9 7
M9788DAA
Transmission Control Cable Removal.
0729-3
TM 9-2320-272-23-4
0729
INSTALLATION 1. 2. 3. 4. 5. Feed transmission select lever end of PTO control cable (Figure 3, Item 4) through rear of PTO control panel (Figure 3, Item 15) and into grommet (Figure 3, Item 3). Attach PTO cable clevis (Figure 3, Item 13) to PTO control panel end of cable (Figure 3, Item 4) with nut (Figure 3, Item 10). Install PTO cable clevis (Figure 3, Item 13) on PTO control lever (Figure 3, Item 1) with clevis pin (Figure 3, Item 14), washer (Figure 3, Item 12), and cotter pin (Figure 3, Item 11). Install PTO control cable (Figure 3, Item 4) on PTO control panel (Figure 3, Item 15) with two screws (Figure 3, Item 2), spacer (Figure 3, Item 5), clamp (Figure 3, Item 6), and two locknuts (Figure 3, Item 7). Install PTO control panel access cover (Figure 3, Item 8) on PTO control panel (Figure 3, Item 15) with six screws (Figure 3, Item 9).
1 15 2
14 13 12 11
10 4 5 6 8 9 7
M9789DAA
Figure 3.
Transmission Control Cable Installation.
0729-4
TM 9-2320-272-23-4
0729
INSTALLATION - Continued 6. 7. 8. Pull PTO control cable (Figure 4, Item 7) down to PTO from engine compartment and install PTO cable pin (Figure 4, Item 8) on end of PTO control cable. Connect PTO cable pin (Figure 4, Item 8) to PTO select lever (Figure 4, Item 9) with washer (Figure 4, Item 10) and cotter pin (Figure 4, Item 11). Attach PTO control cable (Figure 4, Item 7) to PTO cable bracket (Figure 4, Item 3) with clamp (Figure 4, Item 6), spacer plate (Figure 4, Item 4), two screws (Figure 4, Item 5), and locknuts (Figure 4, Item 2). Close transmission dipstick access door (Figure 4, Item 1) inside of cab.
9.
1 2 11
10 9 3 4
8
5
M6109DAA
Transmission Control Cable Installation.
Start engine and check transmission PTO for proper operation. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0729-5/6 blank
TM 9-2320-272-23-4
0730
FIELD MAINTENANCE TRANSMISSION POWER TAKEOFF (PTO) CONTROL CABLE REPLACEMENT (M939A2)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin (Volume 5, WP 0827, Table 1, Item 331) Qty: 1 Cotter Pin Materials/Parts (cont.) (Volume 5, WP 0827, Table 1, Item 333) Qty: 1 Locknut (Volume 5, WP 0827, Table 1, Item 256) Qty: 2 Equipment Condition Parking brake set. (TM 9-2320-272-10) Exhaust pipe removed. (Volume 2, WP 0276)
0730-1
TM 9-2320-272-23-4
0730
REMOVAL 1. 2. 3. Remove cotter pin (Figure 1, Item 11), washer (Figure 1, Item 12), and PTO control cable (Figure 1, Item 7) from PTO select lever (Figure 1, Item 13). Discard cotter pin. Loosen nut (Figure 1, Item 2) and remove cable pin (Figure 1, Item 1) from PTO control cable (Figure 1, Item 7). Remove two locknuts (Figure 1, Item 9), screws (Figure 1, Item 6), clamp (Figure 1, Item 5), PTO control cable (Figure 1, Item 7), and spacer (Figure 1, Item 4) from bracket (Figure 1, Item 8). Discard locknuts.
NOTE
Perform Step (4) only if bracket requires replacement. 4. Remove two screws (Figure 1, Item 3) and bracket (Figure 1, Item 8) from PTO (Figure 1, Item 10).
1 2 3
13 12
8 9 11 7
10
M9790DAA
Figure 1. Transmission PTO Control Cable Removal (M939A2).
0730-2
TM 9-2320-272-23-4
0730
REMOVAL - Continued 5. 6. 7. 8. 9. Remove six screws (Figure 2, Item 3) and access cover (Figure 2, Item 6) from shift panel (Figure 2, Item 16). Remove two nuts (Figure 2, Item 10), screws (Figure 2, Item 14), clamp (Figure 2, Item 13), PTO control cable (Figure 2, Item 9), and spacer (Figure 2, Item 12) from shift panel (Figure 2, Item 16). Remove cotter pin (Figure 2, Item 2), washer (Figure 2, Item 4), clevis pin (Figure 2, Item 8), and control cable (Figure 2, Item 9) from control lever (Figure 2, Item 1). Discard cotter pin. Loosen nut (Figure 2, Item 7) and remove cable clevis (Figure 2, Item 5) from PTO control cable (Figure 2, Item 9). Remove grommet (Figure 2, Item 11) and PTO control cable (Figure 2, Item 9) from firewall (Figure 2, Item 15).
16 15
4 5 8 6 7
14 13 12
9 11 10
Figure 2. Transmission PTO Control Cable Removal (M939A2). END OF TASK
M9792DAA
0730-3
TM 9-2320-272-23-4
0730
INSTALLATION 1. 2. 3. 4. 5. 6. Insert PTO control cable (Figure 3, Item 9) through hole in firewall (Figure 3, Item 15). Place grommet (Figure 3, Item 11) on PTO control cable (Figure 3, Item 9) and install on firewall (Figure 3, Item 15). Install cable clevis (Figure 3, Item 5) on control cable (Figure 3, Item 9). Tighten nut (Figure 3, Item 7) against cable clevis. Install PTO control cable (Figure 3, Item 9) on control lever (Figure 3, Item 1) with clevis pin (Figure 3, Item 8), washer (Figure 3, Item 4), and cotter pin (Figure 3, Item 2). Install spacer (Figure 3, Item 12) and PTO control cable (Figure 3, Item 9) on shift panel (Figure 3, Item 16) with clamp (Figure 3, Item 13), two screws (Figure 3, Item 14), and nuts (Figure 3, Item 10). Install access cover (Figure 3, Item 6) on shift panel (Figure 3, Item 16) with six screws (Figure 3, Item 3).
16 15
4 5 8 6 7
14 13 12
9 11 10
Figure 3. Transmission PTO Control Cable Installation (M939A2).
M6110DAA
0730-4
TM 9-2320-272-23-4
0730
NOTE
Perform Step (7) if bracket was removed. 7. 8. 9. 10. Install bracket (Figure 4, Item 8) on PTO (Figure 4, Item 10) with two screws (Figure 4, Item 3). Install cable pin (Figure 4, Item 1) on PTO control cable (Figure 4, Item 7). Tighten nut (Figure 4, Item 2) against cable pin. Install PTO control cable (Figure 4, Item 7) on select lever (Figure 4, Item 13) with washer (Figure 4, Item 12) and cotter pin (Figure 4, Item 11). Install spacer (Figure 4, Item 4) and PTO control cable (Figure 4, Item 7) on bracket (Figure 4, Item 8) with clamp (Figure 4, Item 5), two screws (Figure 4, Item 6), and locknuts (Figure 4, Item 9).
1 2 3
13 12
8 9 11 7
10
M9791DAA
Transmission PTO Control Cable Installation (M939A2).
Install exhaust pipe. (Volume 2, WP 0276) Start engine and check transmission PTO for proper operation. (TM 9-2320-272-10)
0730-5/6 blank
TM 9-2320-272-23-4
0731
FIELD MAINTENANCE CARGO BODY COVER BOWS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Tarpaulins, curtains, and extensions removed. (TM 9-2320-272-10)
0731-1
TM 9-2320-272-23-4
0731
REMOVAL 1. 2. 3. Remove two screws (Figure 1, Item 6) and stake (Figure 1, Item 7) from corner sections (Figure 1, Item 1). Rotate two latches (Figure 1, Item 2) from rivets (Figure 1, Item 8) and remove corner sections (Figure 1, Item 1) from bow (Figure 1, Item 3). Remove screw (Figure 1, Item 4) and strap (Figure 1, Item 5) from corner sections (Figure 1, Item 1).
2 1
3 2
2 1 4
1 5
M5285DAA
Cargo Body Cover Bows Removal.
0731-2
TM 9-2320-272-23-4
0731
INSTALLATION 1. 2. 3. Install strap (Figure 2, Item 5) on corner sections (Figure 2, Item 1) with screw (Figure 2, Item 4). Insert long end of corner sections (Figure 2, Item 1) over bow (Figure 2, Item 3) and rotate two latches (Figure 2, Item 2) over rivets (Figure 2, Item 8). Install stake (Figure 2, Item 7) on corner sections (Figure 2, Item 1) with two screws (Figure 2, Item 6).
2 1
3 2
2 1 4
1 5
M5286DAA
Figure 2. Cargo Body Cover Bows Installation. END OF TASK
0731-3
TM 9-2320-272-23-4
0731
FOLLOW-ON MAINTENANCE Install tarpaulin, curtains, and extensions. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0731-4
TM 9-2320-272-23-4
0732
FIELD MAINTENANCE CAB TURNBUTTONS AND LASHING HOOKS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 274) Qty: 2 Equipment Condition Parking brake set. (TM 9-2320-272-10) Remove cab cover. (TM 9-2320-272-10)
0732-1
TM 9-2320-272-23-4
0732
REMOVAL 1. Remove turnbutton (Figure 1, Item 1) from cab side rail (Figure 1, Item 2).
NOTE
Center lashing hooks have only two screws. 2. Remove two locknuts (Figure 1, Item 7), screws (Figure 1, Item 5), and forward lashing hook (Figure 1, Item 4) from rear of cab (Figure 1, Item 6). Discard locknuts.
8 4
7 6 5 4
M5194DAA
Figure 1. Cab Turnbuttons and Lashing Hooks Removal. END OF TASK
0732-2
TM 9-2320-272-23-4
0732
INSTALLATION
NOTE
Center lashing hooks have only two screws. 1. 2. Install forward lashing hook (Figure 2, Item 4) on rear of cab (Figure 2, Item 6) with two screws (Figure 2, Item 5) and locknuts (Figure 2, Item 7). Install turnbutton (Figure 2, Item 1) on cab side rail (Figure 2, Item 2).
8 4
7 6 5 4
M5195DAA
Cab Turnbuttons and Lashing Hooks Installation.
0732-3/4 blank
TM 9-2320-272-23-4
0732
FOLLOW-ON MAINTENANCE Install cab cover. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0732-4
TM 9-2320-272-23-4
0733
FIELD MAINTENANCE CAB TOP SEAL AND RETAINER REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Adhesive, Silicone Rubber (Volume 5, WP 0825, Table 1, Item 2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Remove cab cover. (TM 9-2320-272-10)
REMOVAL 1. 2. 3. Remove rubber seals (Figure 1, Items 1 and 6) from cab pillar (Figure 1, Item 3). Remove nine screws (Figure 1, Item 7) and retainer (Figure 1, Item 2) from cab pillar (Figure 1, Item 3). Remove six screws (Figure 1, Item 5) and retainer (Figure 1, Item 4) from cab pillar (Figure 1, Item 3).
3 2 1
7 6 5 4
M5215DAA
Cab Top Seal and Retainer Repair.
0733-1
TM 9-2320-272-23-4
0733
INSTALLATION 1. 2. Install retainers (Figure 2, Items 4 and 2) on cab pillar (Figure 2, Item 3) with nine screws (Figure 2, Item 7) and six screws (Figure 2, Item 5). Apply light coat of adhesive to rubber seals (Figure 2, Items 1 and 6) and install on cab pillar (Figure 2, Item 3).
3 2 1
7 6 5 4
M5216DAA
Figure 2. Cab Top Seal and Retainer Installation. END OF TASK FOLLOW-ON MAINTENANCE Install cab cover. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0733-2
TM 9-2320-272-23-4
0734
FIELD MAINTENANCE CARGO LOWER WHEEL SPLASH GUARD REPLACEMENT
REMOVAL Remove five locknuts (Figure 1, Item 2), screws (Figure 1, Item 5), lower splash guard (Figure 1, Item 3), and retainer (Figure 1, Item 4) from upper splash guard (Figure 1, Item 1). Discard locknuts.
5 4 3 2
M5290DAA
Lower Wheel Splash Guard Replacement.
0734-1
TM 9-2320-272-23-4
0734
INSTALLATION Install retainer (Figure 1, Item 4) and lower splash guard (Figure 1, Item 3) on upper splash guard (Figure 1, Item 1) with five screws (Figure 1, Item 5) and locknuts (Figure 1, Item 2).
5 4 3 2
M5289DAA
Figure 2. Lower Wheel Splash Guard Installation. END OF TASK END OF WORK PACKAGE
0734-2
TM 9-2320-272-23-4
0735
FIELD MAINTENANCE WINDSHIELD WIPER CONTROL VALVE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Tape, Antiseizing (Volume 5, WP 0825, Table 1, Item 65) Lockwasher (Volume 5, WP 0827, Table 1, Item 264) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Air reservoirs drained. (TM 9-2320-272-10)
0735-1
TM 9-2320-272-23-4
0735
REMOVAL
WARNING
Do not disconnect air lines or hoses before draining air reservoirs. Small parts under pressure may shoot out with high velocity. Failure to comply may result in injury or death to personnel.
NOTE
Tag air lines for installation. 1. 2. 3. 4. 5. 6. Remove setscrew (Figure 1, Item 6) and remove knob (Figure 1, Item 5) from shaft (Figure 1, Item 4). Remove nut (Figure 1, Item 7), lockwasher (Figure 1, Item 8), and control valve (Figure 1, Item 10) from instrument panel (Figure 1, Item 9). Discard lockwasher. Remove clamp (Figure 1, Item 2) and disconnect wiper motor run delivery line (Figure 1, Item 1) from adapter (Figure 1, Item 3). Disconnect manifold tee supply line (Figure 1, Item 14) from adapter (Figure 1, Item 15). Remove clamp (Figure 1, Item 12) and disconnect motor park delivery line (Figure 1, Item 13) from adapter (Figure 1, Item 11). Remove adapters (Figure 1, Items 3, 11, and 15) from control valve (Figure 1, Item 10).
0735-2
TM 9-2320-272-23-4
0735
REMOVAL - Continued
5 1 2 3 4 8 7 15 14 10 11 13 12 9 6
M6206DAA
Windshield Wiper Control Valve Removal.
0735-3
TM 9-2320-272-23-4
0735
INSTALLATION
NOTE
If new wiper control valve is being installed, use fittings from old valve. Clean all male pipe threads and wrap with antiseize tape before installation. 1. 2. 3. 4. 5. 6. Install adapters (Figure 2, Items 3, 11, and 15) on control valve (Figure 2, Item 10). Connect motor park delivery line (Figure 2, Item 13) to adapter (Figure 2, Item 11) with clamp (Figure 2, Item 12). Connect manifold tee supply line (Figure 2, Item 14) to adapter (Figure 2, Item 15). Connect wiper motor run delivery line (Figure 2, Item 1) to adapter (Figure 2, Item 3) with clamp (Figure 2, Item 2). Install control valve (Figure 2, Item 10) on instrument panel (Figure 2, Item 9) with lockwasher (Figure 2, Item 8) and nut (Figure 2, Item 7). Install knob (Figure 2, Item 5) on shaft (Figure 2, Item 4) with setscrew (Figure 2, Item 6).
5 1 2 3 4 8 7 15 14 10 11 13 12 9 6
M9472DAA
Windshield Wiper Control Valve Installation.
0735-4
TM 9-2320-272-23-4
0735
FOLLOW-ON MAINTENANCE Start engine and allow air pressure to build to normal operating range. Check for air leaks at wiper control valve. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0735-5/6 blank
TM 9-2320-272-23-4
0736
FIELD MAINTENANCE WINDSHIELD WIPER BLADE, WIPER ARM, AND WIPER MOTOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Wrench, Torque, Click, Ratcheting, 3/8" Drive, 75 Ft-Lb (Volume 5, WP 0826, Table 1, Item 62) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Tape, Antiseizing (Volume 5, WP 0825, Table 1, Item 65) Leather Washer Materials/Parts (cont.) (Volume 5, WP 0827, Table 1, Item 230) Qty: 1 Locknut (Volume 5, WP 0827, Table 1, Item 304) Qty: 1 Locknut (Volume 5, WP 0827, Table 1, Item 325) Qty: 2 Lockwasher (Volume 5, WP 0827, Table 1, Item 385) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10) Air reservoir drained. (TM 9-2320-272-10)
0736-1
TM 9-2320-272-23-4
0736
REMOVAL
WARNING
CAUTION
Cap or plug all openings immediately after disconnecting lines or hoses to prevent contamination. Failure to do so may result in system damage or injury to personnel. 1. Remove locknut (Figure 1, Item 10), screw (Figure 1, Item 11), and wiper blade (Figure 1, Item 12) from wiper arm (Figure 1, Item 7). Discard locknut.
NOTE
Mark position of wiper arm for installation. 2. 3. 4. 5. 6. 7. 8. 9. Remove nut (Figure 1, Item 9), lockwasher (Figure 1, Item 8), and wiper arm (Figure 1, Item 7) from wiper motor shaft (Figure 1, Item 1). Discard lockwasher. Remove knurled drive (Figure 1, Item 6) from wiper motor shaft (Figure 1, Item 1). Remove nut (Figure 1, Item 5), washer (Figure 1, Item 4), and leather washer (Figure 1, Item 3) from wiper motor shaft (Figure 1, Item 13). Discard leather washer. Remove hose clamps (Figure 1, Item 14) and (Figure 1, Item 17) and hoses (Figure 1, Items 15 and 16) from adapter fittings (Figure 1, Item 23) and (Figure 1, Item 21). Remove two locknuts (Figure 1, Item 20), screws (Figure 1, Item 18), wiper motor (Figure 1, Item 22), and wiper motor bracket (Figure 1, Item 19) from windshield frame (Figure 1, Item 2). Discard locknuts. Remove two screws (Figure 1, Item 26), bracket (Figure 1, Item 19), and two spacers (Figure 1, Item 25) from wiper motor (Figure 1, Item 22). Remove adapter fittings (Figure 1, Item 21) and (Figure 1, Item 23) from wiper motor (Figure 1, Item 22). Remove muffler (Figure 1, Item 24) from wiper motor (Figure 1, Item 22).
0736-2
TM 9-2320-272-23-4
0736
REMOVAL - Continued
1 3 4 13 5
14
15
16
17
18
7 8
26 9 24 25
19 10 23 22 20 21
12
11
M5127DAA
Windshield Wiper Blade, Wiper Arm, and Wiper Motor Removal.
0736-3
TM 9-2320-272-23-4
0736
INSTALLATION 1. Install muffler (Figure 2, Item 12) on wiper motor (Figure 2, Item 10).
NOTE
Wrap male pipe threads with antiseize tape before installation. 2. 3. 4. 5. 6. 7. 8. 9. Install adapter fittings (Figure 2, Item 9) and (Figure 2, Item 11) in wiper motor (Figure 2, Item 10). Install bracket (Figure 2, Item 7) on wiper motor (Figure 2, Item 10) with two spacers (Figure 2, Item 13) and screws (Figure 2, Item 14). Install wiper motor (Figure 2, Item 10) and bracket (Figure 2, Item 7) on windshield frame (Figure 2, Item 5) with two screws (Figure 2, Item 6) and locknuts (Figure 2, Item 8). Install hoses (Figure 2, Items 2 and 3) on adapter fittings (Figure 2, Item 11) and (Figure 2, Item 9) with hose clamps (Figure 2, Items 1 and 4). Install leather washer (Figure 2, Item 16), washer (Figure 2, Item 17), and nut (Figure 2, Item 18) on wiper motor shaft (Figure 2, Item 10). Install knurled drive (Figure 2, Item 19) on wiper motor shaft (Figure 2, Item 15). Install wiper arm (Figure 2, Item 20) on wiper motor shaft (Figure 2, Item 15) with lockwasher (Figure 2, Item 21) and nut (Figure 2, Item 22). Tighten nut 15 to 20 lb-ft (20 to 27 Nm). Install wiper blade (Figure 2, Item 25) on wiper arm (Figure 2, Item 20) with screw (Figure 2, Item 24) and locknut (Figure 2, Item 23). Tighten locknut 15 to 20 lb-ft (20 to 27 Nm).
6 15
5 16
14 12 13 10 7 11 10 9 8
17
18 19
20 22 21
23
25
24
M5127DAA
Windshield Wiper Blade, Wiper Arm, and Wiper Motor Removal.
0736-4
TM 9-2320-272-23-4
0736
FOLLOW-ON MAINTENANCE Start engine and check for air leaks and proper operation. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0736-5/6 blank
TM 9-2320-272-23-4
0737
FIELD MAINTENANCE WINDSHIELD WIPER RESERVOIR, JET, CONTROL, AND WASHER HOSES REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Tape, Antiseizing (Volume 5, WP 0825, Table 1, Item 65) Locknut (Volume 5, WP 0827, Table 1, Item 312) Qty: 3 Lockwasher (Volume 5, WP 0827, Table 1, Item 264) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Air reservoir drained. (TM 9-2320-272-10) Wheels chocked. (TM 9-2320-272-10) Hood raised and secured. (TM 9-2320-272-10) Instrument cluster removed. (Volume 2, WP 0310)
0737-1
TM 9-2320-272-23-4
0737
WASHER HOSES REMOVAL 1. 2. 3. 4. 5. 6. 7. Remove wire clamp (Figure 1, Item 6) and air supply line (Figure 1, Item 7) from washer control valve outlet adapter (Figure 1, Item 5). Remove wire clamp (Figure 1, Item 11) and air supply line (Figure 1, Item 7) from washer bottle air inlet adapter (Figure 1, Item 9). Remove air supply line (Figure 1, Item 7) from grommet (Figure 1, Item 8) and firewall (Figure 1, Item 14). Disconnect washer jet supply tube (Figure 1, Item 12) from outlet adapter (Figure 1, Item 10). Disconnect washer jet supply tube (Figure 1, Item 12) from tee (Figure 1, Item 13), grommet (Figure 1, Item 3), and firewall (Figure 1, Item 14). Disconnect two windshield washer jet supply tubes (Figure 1, Item 2) from washer jet adapters (Figure 1, Item 1). Remove two windshield washer jet supply tubes (Figure 1, Item 2) from tee (Figure 1, Item 13) under cowl (Figure 1, Item 4).
5 6 1 7 13 12 14
11 8 10 7 9
M5138DAA
Figure 1. Windshield Washer Hoses Removal. END OF TASK
0737-2
TM 9-2320-272-23-4
0737
WASHER HOSES INSTALLATION 1. 2. 3. 4. 5. 6. 7. Connect two windshield washer jet supply tubes (Figure 2, Item 2) to tee (Figure 2, Item 13) under cowl (Figure 2, Item 4). Connect two windshield washer jet supply tubes (Figure 2, Item 2) to washer jet adapters (Figure 2, Item 1). Push washer jet supply tube (Figure 2, Item 12) through grommet (Figure 2, Item 3) in firewall (Figure 2, Item 14) and connect to tee (Figure 2, Item 13). Connect washer jet supply tube (Figure 2, Item 12) to outlet adapter (Figure 2, Item 10). Install air supply line (Figure 2, Item 7) on washer bottle air inlet adapter (Figure 2, Item 9) with wire clamp (Figure 2, Item 11). Push air supply line (Figure 2, Item 7) through grommet (Figure 2, Item 8) in firewall (Figure 2, Item 14). Install air supply line (Figure 2, Item 7) on washer control valve outlet adapter (Figure 2, Item 5) with wire clamp (Figure 2, Item 6).
1 5 1 6
7 13 12 14
11 8 7 9
M5138DAA
10
Figure 2. Windshield Washer Hoses Installation. END OF TASK
0737-3
TM 9-2320-272-23-4
0737
RESERVOIR REMOVAL
WARNING
NOTE
Tag all air lines for installation. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Remove setscrew (Figure 3, Item 13) and knob (Figure 3, Item 14) from windshield wiper control (Figure 3, Item 11). Remove nut (Figure 3, Item 1), lockwasher (Figure 3, Item 2), and windshield wiper control (Figure 3, Item 11) from instrument panel (Figure 3, Item 4). Discard lockwasher. Remove clamp (Figure 3, Item 10) and hose (Figure 3, Item 12) from windshield wiper control (Figure 3, Item 11). Remove hose (Figure 3, Item 9) and elbow (Figure 3, Item 8) from windshield wiper control (Figure 3, Item 11). Remove clamp (Figure 3, Item 6) and duct hose (Figure 3, Item 5) from defrost duct (Figure 3, Item 3). Pull duct hose from firewall (Figure 3, Item 7). Disconnect hoses (Figure 3, Item 17) and (Figure 3, Item 31) from jets (Figure 3, Items 15 and 18). Remove wingnuts (Figure 3, Item 19) and (Figure 3, Item 33) and jets (Figure 3, Items 15 and 18) from cab (Figure 3, Item 32). Remove hoses (Figure 3, Item 17), (Figure 3, Item 30), and (Figure 3, Item 31) from tee (Figure 3, Item 16). Remove clamps (Figure 3, Item 22) and (Figure 3, Item 23) and hoses (Figure 3, Items 12 and 30) from windshield wiper reservoir cap (Figure 3, Item 24). Remove windshield wiper reservoir cap (Figure 3, Item 24) from windshield wiper reservoir (Figure 3, Item 25). Remove windshield wiper reservoir (Figure 3, Item 25) from bracket (Figure 3, Item 26). Remove three locknuts (Figure 3, Item 29), screws (Figure 3, Item 27), and bracket (Figure 3, Item 26) from mounting bracket (Figure 3, Item 28). Discard locknuts. Remove grommets (Figure 3, Item 20) and (Figure 3, Item 21) and hoses (Figure 3, Items 12 and 30) from firewall (Figure 3, Item 7).
0737-4
TM 9-2320-272-23-4
0737
RESERVOIR REMOVAL - Continued
2 1
14 13 12 8 9 15 33 32 11 16 10 17 18 19 20 21 7 31 30 29 24 12 22 23 7 6
28 25 26 27
Figure 3. END OF TASK Windshield Wiper Reservoir Removal.
M5136DAA
0737-5
TM 9-2320-272-23-4
0737
RESERVOIR INSTALLATION
NOTE
Wrap all male threads with antiseize tape prior to installation. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Install bracket (Figure 4, Item 26) on mounting bracket (Figure 4, Item 28) with three screws (Figure 4, Item 27) and locknuts (Figure 4, Item 29). Install windshield wiper reservoir (Figure 4, Item 25) on bracket (Figure 4, Item 26). Install windshield wiper reservoir cap (Figure 4, Item 24) on reservoir (Figure 4, Item 25). Install hoses (Figure 4, Item 12) and (Figure 4, Item 30) on windshield wiper reservoir cap (Figure 4, Item 24) with clamps (Figure 4, Item 22) and (Figure 4, Item 23). Insert hoses (Figure 4, Item 12) and (Figure 4, Item 30) through holes in firewall (Figure 4, Item 7). Install hoses (Figure 4, Item 17), (Figure 4, Item 30), and (Figure 4, Item 31) on tee (Figure 4, Item 16). Install jets (Figure 4, Item 15) and (Figure 4, Item 18) on cab (Figure 4, Item 32) with wing nuts (Figure 4, Item 33) and (Figure 4, Item 19). Connect hoses (Figure 4, Item 31) and (Figure 4, Item 17) on jets (Figure 4, Item 15) and (Figure 4, Item 18). Place grommets (Figure 4, Items 20 and 21) on hoses (Figure 4, Items 12 and 30) and install on firewall (Figure 4, Item 7). Install elbow (Figure 4, Item 8) and hose (Figure 4, Item 9) on windshield wiper control (Figure 4, Item 11). Install hose (Figure 4, Item 12) on windshield wiper control (Figure 4, Item 11) with clamp (Figure 4, Item 10). Install windshield wiper control (Figure 4, Item 11) on instrument panel (Figure 4, Item 4) with lockwasher (Figure 4, Item 2) and nut (Figure 4, Item 1). Install knob (Figure 4, Item 14) on windshield wiper control (Figure 4, Item 11) with setscrew (Figure 4, Item 13). Install duct hose (Figure 4, Item 5) on defrost duct (Figure 4, Item 3) with clamp (Figure 4, Item 6).
0737-6
TM 9-2320-272-23-4
0737
RESERVOIR INSTALLATION - Continued
2 1
14 13 12 8 9 15 33 32 11 16 10 17 18 19 20 21 7 31 30 29 24 12 22 23 7 6
28 25 26 27
Figure 4. END OF TASK Windshield Wiper Reservoir Installation.
M5137DAA
0737-7
TM 9-2320-272-23-4
0737
FOLLOW-ON MAINTENANCE 1. 2. Install instrument cluster. (Volume 2, WP 0310) Start engine and check for leaks and proper operation. (TM 9-2320-272-10)
0737-8
TM 9-2320-272-23-4
0738
FIELD MAINTENANCE REARVIEW MIRROR AND BRACE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 272) Qty: 2 Locknut (Volume 5, WP 0827, Table 1, Item 289) Qty: 5 Locknut (Volume 5, WP 0827, Table 1, Item 320) Qty: 2 Materials/Parts (cont.) Lockwasher (Volume 5, WP 0827, Table 1, Item 403) Qty: 1 Screw Assembled Lockwasher (Volume 5, WP 0827, Table 1, Item 171) Qty: 5 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0738-1
TM 9-2320-272-23-4
0738
REMOVAL 1. 2. 3. 4. 5. Remove two locknuts (Figure 1, Item 9) and washers (Figure 1, Item 8) from mirror (Figure 1, Item 7). Discard locknuts. Remove rearview mirror (Figure 1, Item 7) and two spacers (Figure 1, Item 6) from rearview mirror brace (Figure 1, Item 4). Remove nut (Figure 1, Item 19), lockwasher (Figure 1, Item 20), and screw (Figure 1, Item 38) from two clamp halves (Figure 1, Item 21). Discard lockwasher. Remove screw assembled lockwasher (Figure 1, Item 35), two clamp halves (Figure 1, Item 21), and convex mirror (Figure 1, Item 5) from upper brace (Figure 1, Item 34). Discard screw assembled lockwasher. Remove locknut (Figure 1, Item 28), washer (Figure 1, Item 29), and hinge screw (Figure 1, Item 33) from upper mirror braces (Figure 1, Item 36) and (Figure 1, Item 1) and upper cab door hinge (Figure 1, Item 31). Discard locknut. Push upper mirror braces (Figure 1, Item 36) and (Figure 1, Item 1) away from cab door hinge (Figure 1, Item 31). Insert hinge screw (Figure 1, Item 33) into upper cab door hinge (Figure 1, Item 31). Do not tighten hinge screw. Remove locknut (Figure 1, Item 12), washer (Figure 1, Item 23), and hinge screw (Figure 1, Item 22) from lower mirror brace (Figure 1, Item 11) and lower cab door hinge (Figure 1, Item 24). Discard locknut. Push lower mirror brace (Figure 1, Item 11) away from lower cab door hinge (Figure 1, Item 24). Insert hinge screw (Figure 1, Item 22) into lower cab door hinge (Figure 1, Item 24). Do not tighten hinge screw. Remove locknut (Figure 1, Item 27), washer (Figure 1, Item 26), and screw (Figure 1, Item 32) from front mirror brace (Figure 1, Item 17) and (Figure 1, Item 37) and cab cowl bracket (Figure 1, Item 30). Discard locknut. Remove two locknuts (Figure 1, Item 3), washers (Figure 1, Item 2), gaskets (Figure 1, Item 18), braces (Figure 1, Items 1, 4, 11, 17, 36, and 37) from rod (Figure 1, Item 10) and upper brace (Figure 1, Item 34). Discard locknuts. Open air vent door (Figure 1, Item 25). Remove two locknuts (Figure 1, Item 15), screws (Figure 1, Item 13), cowl plate (Figure 1, Item 14), and bracket (Figure 1, Item 30) from cowl side panel (Figure 1, Item 16). Discard locknuts.
6. 7. 8. 9. 10. 11. 12.
13. 14.
0738-2
TM 9-2320-272-23-4
0738
REMOVAL - Continued
3 2 1 18 17 16 33 30 15 14 26 27 25 13 24 23 22 9 31 29 28 37 36 18 8 38 35 19 32 34 7 20 21 6 9 8 4 5 6
12
10 11 2 3
M5162DAA
Figure 1. Rearview Mirror and Brace Removal. END OF TASK
0738-3
TM 9-2320-272-23-4
0738
INSTALLATION 1. 2. 3. 4. 5. Install bracket (Figure 2, Item 30) and cowl plate (Figure 2, Item 14) on cowl side panel (Figure 2, Item 16) with two screws (Figure 2, Item 13) and two locknuts (Figure 2, Item 15). Install braces (Figure 2, Items 1, 4, 11, 17, 34, 36, and 37), and two gaskets (Figure 2, Item 18) on rod (Figure 2, Item 10) with two washers (Figure 2, Item 2) and locknuts (Figure 2, Item 3). Install mirror braces (Figure 2, Item 37) and (Figure 2, Item 17) on cab cowl bracket (Figure 2, Item 30) with screw (Figure 2, Item 32), washer (Figure 2, Item 26), and locknut (Figure 2, Item 27). Remove hinge screw (Figure 2, Item 33) from top door hinge (Figure 2, Item 31). Position upper mirror brace (Figure 2, Item 1) and mirror brace (Figure 2, Item 36) over upper door hinge (Figure 2, Item 31) and install hinge screw (Figure 2, Item 33) through brace and hinge with washer (Figure 2, Item 29) and locknut (Figure 2, Item 28). Remove hinge screw (Figure 2, Item 22) from lower door hinge (Figure 2, Item 24). Position lower mirror brace (Figure 2, Item 11) over lower door hinge (Figure 2, Item 24) and insert hinge screw (Figure 2, Item 22) through brace and hinge and secure with washer (Figure 2, Item 23) and locknut (Figure 2, Item 12). Install two clamp halves (Figure 2, Item 21) on upper brace (Figure 2, Item 34) with screw (Figure 2, Item 38), lockwasher (Figure 2, Item 20), and nut (Figure 2, Item 19). Install convex mirror (Figure 2, Item 5) on clamp halves (Figure 2, Item 21) with screw assembled lockwasher (Figure 2, Item 35). Position rearview mirror (Figure 2, Item 7) and two spacers (Figure 2, Item 6) on mirror brace (Figure 2, Item 4) and install with two washers (Figure 2, Item 8) and locknuts (Figure 2, Item 9).
6. 7.
8. 9. 10.
0738-4
TM 9-2320-272-23-4
0738
3 2 1 18 17 16 33 30 15 14 26 27 25 13 24 23 22 9 31 29 28 37 36 18 8 38 35 19 32 34 7 20 21 6 9 8 4 5 6
12
10 11 2 3
M5163DAA
Figure 2. Rearview Mirror and Brace Installation. END OF TASK END OF WORK PACKAGE
0738-5/6 blank
TM 9-2320-272-23-4
0739
FIELD MAINTENANCE WASHER CONTROL VALVE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Tape, Antiseizing (Volume 5, WP 0825, Table 1, Item 65) Equipment Condition Air reservoirs drained. (TM 9-2320-272-10) Equipment Condition (cont.) Parking brake set. (TM 9-2320-272-10)
0739-1
TM 9-2320-272-23-4
0739
REMOVAL
WARNING
Do not disconnect air lines or hoses before draining air reservoirs. Small parts under pressure may shoot out with high velocity. Failure to comply may result in injury or death to personnel. 1. 2. 3. 4. Remove setscrew (Figure 1, Item 6) and knob (Figure 1, Item 7) from shaft (Figure 1, Item 10). Remove retaining ring (Figure 1, Item 8), nut (Figure 1, Item 5), washer (Figure 1, Item 4), and washer control valve (Figure 1, Item 3) from instrument panel (Figure 1, Item 9). Remove clamp (Figure 1, Item 11) and washer bottle delivery line (Figure 1, Item 12) from washer control valve (Figure 1, Item 3). Remove manifold tee supply line (Figure 1, Item 1) from elbow (Figure 1, Item 2).
0739-2
TM 9-2320-272-23-4
0739
REMOVAL - Continued
1 2 3
4 10 12 11
8 7
M6205DAA
Washer Control Valve Removal.
0739-3
TM 9-2320-272-23-4
0739
INSTALLATION
NOTE
If new valve is being installed, use fittings from old valve. Wrap all male pipe threads with antiseize tape before installation. 1. 2. 3. 4. Install manifold tee supply line (Figure 2, Item 1) on elbow (Figure 2, Item 2). Install delivery line (Figure 2, Item 12) on washer control valve (Figure 2, Item 3) with clamp (Figure 2, Item 11). Install washer control valve (Figure 2, Item 3) on instrument panel (Figure 2, Item 9) with washer (Figure 2, Item 4) and nut (Figure 2, Item 5). Install retaining ring (Figure 2, Item 8) and knob (Figure 2, Item 7) on shaft (Figure 2, Item 10) with setscrew (Figure 2, Item 6).
1 2 3
4 10 12 11
8 7
M9473DAA
Washer Control Valve Installation.
0739-4
TM 9-2320-272-23-4
0739
FOLLOW-ON MAINTENANCE Start engine and check for air leaks and proper washer control valve operation. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0739-5/6 blank
TM 9-2320-272-23-4
0740
FIELD MAINTENANCE REFLECTORS REPLACEMENT
REMOVAL
NOTE
Reflectors on all vehicles are basically the same. Mounting hardware may differ. This procedure covers replacement of reflectors on cargo dropside vehicle. Remove two nuts (Figure 1, Item 3), screws (Figure 1, Item 4), and reflector (Figure 1, Item 1) from cargo body (Figure 1, Item 2).
2 1 4 3
M5297DAA
Reflectors Removal.
0740-1
TM 9-2320-272-23-4
0740
INSTALLATION Install reflector (Figure 2, Item 1) on cargo body (Figure 2, Item 2) with two screws (Figure 2, Item 4) and nuts (Figure 2, Item 3).
2 1 4 3
M5298DAA
Reflectors Installation.
0740-2
TM 9-2320-272-23-4
0741
FIELD MAINTENANCE FRESH AIR VENT CONTROL CABLE ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin Materials/Parts (cont.) (Volume 5, WP 0827, Table 1, Item 257) Qty: 1 Lockwasher (Volume 5, WP 0827, Table 1, Item 186) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10) Hood raised and secured. (TM 9-2320-272-10)
REMOVAL 1. 2. Remove screw (Figure 1, Item 3), sheet spring nut (Figure 1, Item 5), and clamp bracket (Figure 1, Item 4) from personnel hot water heater (Figure 1, Item 7). Remove cotter pin (Figure 1, Item 6), fresh air control cable (Figure 1, Item 2), and clip (Figure 1, Item 1) from fresh air shutoff rod (Figure 1, Item 8). Discard cotter pin.
3 4
5 6 8 7
M5168DAA
Figure 1.
Fresh Air Vent Control Assembly Removal.
0741-1
TM 9-2320-272-23-4
0741
REMOVAL - Continued 3. 4. 5. Remove eight screws (Figure 2, Item 7) and pull instrument cluster (Figure 2, Item 6) from instrument panel (Figure 2, Item 1). Remove nut (Figure 2, Item 2) and lockwasher (Figure 2, Item 3) from fresh air control handle (Figure 2, Item 5) and slide off fresh air control cable (Figure 2, Item 4) at coiled end. Discard lockwasher. Remove fresh air control handle (Figure 2, Item 5) and fresh air control cable (Figure 2, Item 4) from instrument cluster (Figure 2, Item 6).
6 2
3 5 4
M5170DAA
Fresh Air Vent Control Assembly Removal.
0741-2
TM 9-2320-272-23-4
0741
INSTALLATION 1. 2. 3. 4. 5. Install fresh air control handle (Figure 3, Item 5) and fresh air control cable (Figure 3, Item 4) through hole in instrument cluster (Figure 3, Item 6). Position fresh air control handle (Figure 3, Item 5) against instrument cluster (Figure 3, Item 6) and install with lockwasher (Figure 3, Item 3) and nut (Figure 3, Item 2). Install instrument cluster (Figure 3, Item 6) on instrument panel (Figure 3, Item 1) with eight screws (Figure 3, Item 7). Push fresh air control handle (Figure 3, Item 5) in all the way. Push fresh air control cable (Figure 4, Item 2) through firewall (Figure 4, Item 5).
6 2
3 5 4
M5171DAA
Figure 3. Fresh Air Vent Control Assembly Installation.
0741-3
TM 9-2320-272-23-4
0741
INSTALLATION - Continued 6. 7. 8. 9. Close fresh air shutoff rod (Figure 4, Item 9) before connecting fresh air control cable (Figure 4, Item 2). Install clip (Figure 4, Item 1) and fresh air control cable (Figure 4, Item 2) on fresh air shutoff rod (Figure 4, Item 9) with cotter pin (Figure 4, Item 7). Install fresh air control cable (Figure 4, Item 2) on personnel hot water heater (Figure 4, Item 8) with clamp bracket (Figure 4, Item 4), spring nut (Figure 4, Item 6), and screw (Figure 4, Item 3). Adjust air intake flap (Figure 4, Item 10) to the closed position.
3 4
10 5
6 7 9 8
M5169DAA
Fresh Air Vent Control Assembly Installation.
Check fresh air vent for proper operation. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0741-4
TM 9-2320-272-23-4
0742
FIELD MAINTENANCE DIVERTER ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin (Volume 5, WP 0827, Table 1, Item 257) Qty: 2 Spring Nut (Volume 5, WP 0827, Table 1, Item 427) Qty: 2 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Defrost and heat control levers closed. (TM 9-2320-272-10) Right fender splash shield removed. (WP 0575)
REMOVAL 1. Remove two screw assembled washers (Figure 1, Item 3) and bracket (Figure 1, Item 2) from right side of engine compartment cowl (Figure 1, Item 1).
M5176DAA
Figure 1.
Diverter Assembly Removal.
0742-1
TM 9-2320-272-23-4
0742
REMOVAL - Continued 2. 3. 4. 5. 6. Remove three clamps (Figure 2, Item 6) and ducting hoses (Figure 2, Item 3) from diverter (Figure 2, Item 5) and three adapter flanges (Figure 2, Item 4). Remove screw (Figure 2, Item 19), clamp (Figure 2, Item 18), and retaining clip (Figure 2, Item 8) from defroster control cable bracket (Figure 2, Item 9). Remove cotter pin (Figure 2, Item 20), defroster control cable (Figure 2, Item 21), and spring nut (Figure 2, Item 22) from control rod (Figure 2, Item 7). Discard cotter pin and spring nut. Remove screw (Figure 2, Item 17), clamp (Figure 2, Item 16), and retaining clip (Figure 2, Item 11) from heater control cable bracket (Figure 2, Item 10). Remove cotter pin (Figure 2, Item 14), heater control cable (Figure 2, Item 15), and spring nut (Figure 2, Item 13) from control rod (Figure 2, Item 12). Discard cotter pin and spring nut.
CAUTION
Hold personnel hot water heater and brackets in place during removal of diverter. Both mount to firewall with same screws. 7. Remove four screw assembled washers (Figure 2, Item 23), cage nuts (Figure 2, Item 2), personnel hot water heater bracket (Figure 2, Item 24), and diverter (Figure 2, Item 5) from firewall (Figure 2, Item 1).
3 23 22 21 20 19 18 17 16 15 14 13 6 8 9 10 11 6 3 6 24 1 2 4 5
12
3
Figure 2. Diverter Assembly Removal. END OF TASK
M5178DAA
0742-2
TM 9-2320-272-23-4
0742
INSTALLATION 1. Install diverter (Figure 3, Item 5) on hot water heater bracket (Figure 3, Item 24) and firewall (Figure 3, Item 1) with four screw assembled washers (Figure 3, Item 23) and cage nuts (Figure 3, Item 2).
3 23 22 21 20 19 18 17 16 15 14 13 6 8 9 10 11 6 3 6 24 1 2 4 5
12
3
Figure 3. Diverter Assembly Installation.
M5179DAA
0742-3
TM 9-2320-272-23-4
0742
INSTALLATION - Continued 2. Install three ducting hoses (Figure 3, Item 3) on diverter (Figure 3, Item 5) and adapter flanges (Figure 3, Item 4) with three clamps (Figure 3, Item 6).
M5177DAA
Figure 4. 3. 4. 5. 6. 7.
Diverter Assembly Installation.
Install heater control cable (Figure 3, Item 15) on control rod (Figure 3, Item 12) with spring nut (Figure 3, Item 13) and cotter pin (Figure 3, Item 14). Install heater control cable (Figure 3, Item 15) on heater control cable bracket (Figure 4, Item 10) with clamp (Figure 3, Item 16), screw (Figure 3, Item 17), and retaining clip (Figure 3, Item 11). Install defroster control cable (Figure 3, Item 21) on control rod (Figure 3, Item 7) with spring nut (Figure 3, Item 22) and cotter pin (Figure 3, Item 20). Install defroster control cable (Figure 3, Item 21) on defroster control cable bracket (Figure 3, Item 9) with clamp (Figure 3, Item 18), screw (Figure 3, Item 19), and retaining clip (Figure 3, Item 8). Install bracket (Figure 4, Item 2) to right side engine compartment cowl (Figure 4, Item 1) with two screw assembled washers (Figure 4, Item 3).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install right fender splash shield. (WP 0575) Check heater for proper operation. (TM 9-2320-272-10)
0742-4
TM 9-2320-272-23-4
0743
FIELD MAINTENANCE FRESH AIR INLET DUCTING REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Defrost and heat control levers closed. (TM 9-2320-272-10) Hood raised and secured. (TM 9-2320-272-10)
0743-1
TM 9-2320-272-23-4
0743
REMOVAL 1. 2. 3. Loosen clamp (Figure 1, Item 1) and remove fresh air ducting (Figure 1, Item 5) from adapter flange (Figure 1, Item 2). Remove two nuts (Figure 1, Item 6), screws (Figure 1, Item 9), and clamps (Figure 1, Item 3) from fresh air ducting (Figure 1, Item 5) and hood (Figure 1, Item 4). Loosen clamp (Figure 1, Item 8) and remove fresh air ducting (Figure 1, Item 5) from flange (Figure 1, Item 7).
2 1
9 3 3 4
6 7
8
M5180DAA
Figure 1. Fresh Air Inlet Ducting Removal. END OF TASK
0743-2
TM 9-2320-272-23-4
0743
INSTALLATION 1. 2. 3. Install fresh air ducting (Figure 2, Item 5) on flange (Figure 2, Item 7) with clamp (Figure 2, Item 8). Install fresh air ducting (Figure 2, Item 5) on hood (Figure 2, Item 4) with two clamps (Figure 2, Item 3), screws (Figure 2, Item 9), and nuts (Figure 2, Item 6). Install fresh air ducting (Figure 2, Item 5) on adapter flange (Figure 2, Item 2) with clamp (Figure 2, Item 1).
2 1
9 3 3 4
5 6 7
8
M5181DAA
Fresh Air Inlet Ducting Installation.
0743-3/4 blank
TM 9-2320-272-23-4
0744
FIELD MAINTENANCE CAB HEAT AND DEFROST AIR DUCTING REPLACEMENT
REMOVAL 1. 2. Remove eight screws (Figure 1, Item 5) and instrument cluster (Figure 1, Item 7) from instrument panel (Figure 1, Item 6). Loosen six clamps (Figure 1, Item 4) and remove cab heat ducting hose (Figure 1, Item 9) and defrost ducting hoses (Figure 1, Items 1 and 10) from diverter (Figure 1, Item 2), exhaust flange (Figure 1, Item 8), and two defrost air flanges (Figure 1, Item 3).
1
7 8 5 10 9 10 2
3
M5182DAA
Figure 1. Cab Heat and Defrost Air Ducting Removal. END OF TASK
0744-1
TM 9-2320-272-23-4
0744
INSTALLATION 1. 2. 3. Install cab heat ducting hose (Figure 2, Item 9) on diverter (Figure 2, Item 2) and exhaust flange (Figure 2, Item 8) with clamps (Figure 2, Item 4). Install defrost ducting hoses (Figure 2, Items 1 and 10) on defrost air flanges (Figure 2, Item 3) with clamps (Figure 2, Item 4). Install instrument cluster (Figure 2, Item 7) on instrument panel (Figure 2, Item 6) with eight screws (Figure 2, Item 5).
1 6
10
5 10
4
3
M5183DAA
Cab Heat and Defrost Air Ducting Installation.
0744-2
TM 9-2320-272-23-4
0745
FIELD MAINTENANCE DEFROST AND HEAT CONTROLS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin Materials/Parts (cont.) (Volume 5, WP 0827, Table 1, Item 257) Qty: 2 Spring Nut (Volume 5, WP 0827, Table 1, Item 427) Qty: 2 Equipment Condition Parking brake set. (TM 9-2320-272-10)
0745-1
TM 9-2320-272-23-4
0745
REMOVAL
NOTE
Tag all cables for installation. 1. 2. 3. 4. Remove screw (Figure 1, Item 12), clamp (Figure 1, Item 16), defrost cable (Figure 1, Item 14), and retaining clip (Figure 1, Item 1) from diverter bracket (Figure 1, Item 3). Remove cotter pin (Figure 1, Item 13), defrost cable (Figure 1, Item 14), and spring nut (Figure 1, Item 15) from control rod (Figure 1, Item 2). Discard cotter pin and spring nut. Remove screw (Figure 1, Item 11), clamp (Figure 1, Item 10), heat control cable (Figure 1, Item 9), and retaining clip (Figure 1, Item 5) from diverter bracket (Figure 1, Item 4). Remove cotter pin (Figure 1, Item 8), heat control cable (Figure 1, Item 9), and spring nut (Figure 1, Item 7) from control rod (Figure 1, Item 6). Discard cotter pin and spring nut.
1 15 14 16
2 13 12 11 10 9 5 6 8 3 4
7
M5172DAA
Figure 1.
Defrost and Heat Controls Removal.
0745-2
TM 9-2320-272-23-4
0745
REMOVAL - Continued 5. 6. 7. Remove eight screws (Figure 2, Item 7) and pull instrument cluster (Figure 2, Item 6) away from instrument panel (Figure 2, Item 8). Remove two nuts (Figure 2, Item 2), washers (Figure 2, Item 1), and defrost cable (Figure 2, Item 4) from instrument cluster (Figure 2, Item 8). Remove heat control cable handle (Figure 2, Item 3), heat control cable (Figure 1, Item 9), defrost cable (Figure 2, Item 4), and defrost control handle (Figure 2, Item 5) from instrument cluster (Figure 2, Item 6).
2 1
7
M5174DAA
Figure 2. Defrost and Heat Controls Removal. END OF TASK
0745-3
TM 9-2320-272-23-4
0745
INSTALLATION 1. Install heat control cable handle (Figure 3, Item 3), heat control cable (Figure 4, Item 9), defrost control handle (Figure 3, Item 5), and defrost cable (Figure 3, Item 4) on instrument cluster (Figure 3, Item 6) with two washers (Figure 3, Item 1) and nuts (Figure 3, Item 2). Route cables (Figure 3, Item 4) and (Figure 4, Item 9) to diverter brackets (Figure 4, Items 3 and 4). Install instrument cluster (Figure 3, Item 6) on instrument panel (Figure 3, Item 8) with eight screws (Figure 3, Item 7). Push heat control handle (Figure 3, Item 3) and defrost handle (Figure 3, Item 5) in all the way.
2 1
2. 3. 4.
7
M5175DAA
Figure 3.
Defrost and Heat Controls Installation.
0745-4
TM 9-2320-272-23-4
0745
INSTALLATION - Continued 5. 6. 7. 8. Install heat control cable (Figure 4, Item 9) on control rod (Figure 4, Item 6) with spring nut (Figure 4, Item 7) and cotter pin (Figure 4, Item 8). Install heat control cable (Figure 4, Item 9) on diverter bracket (Figure 4, Item 4) with retaining clip (Figure 4, Item 5), clamp (Figure 4, Item 10), and screw (Figure 4, Item 11). Install defrost control cable (Figure 4, Item 14) on control rod (Figure 4, Item 2) with spring nut (Figure 4, Item 1) and cotter pin (Figure 4, Item 13). Install defrost control cable (Figure 4, Item 14) on diverter bracket (Figure 4, Item 3) with retaining clip (Figure 4, Item 1), clamp (Figure 4, Item 16), and screw (Figure 4, Item 12).
1 15 14 16
2 13 12 11 10 9 5 6 8 3 4
7
M5173DAA
Defrost and Heat Controls Installation.
Check defrost and heat controls for proper operation. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0745-5/6 blank
TM 9-2320-272-23-4
0746
FIELD MAINTENANCE PERSONNEL HEATER HOSES REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) References Volume 2, WP 0287 Equipment Condition Parking brake set. (TM 9-2320-272-10) Right fender splash shield removed. (WP 0575)
0746-1
TM 9-2320-272-23-4
0746
REMOVAL
NOTE
Have drainage container ready to catch coolant. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. The personnel heater inlet hose and outlet hose are removed the same. This procedure covers the inlet hose. 1. 2. 3. Loosen hose clamp (Figure 1, Item 9) and remove heater inlet hose (Figure 1, Item 1) from elbow (Figure 1, Item 8). Remove nut (Figure 1, Item 6), screw (Figure 1, Item 4), clamp (Figure 1, Item 5), and heater inlet hose (Figure 1, Item 1) from heater (Figure 1, Item 7). Loosen hose clamp (Figure 1, Item 2) and remove heater inlet hose (Figure 1, Item 1) from oil cooler shutoff valve (Figure 1, Item 3).
0746-2
TM 9-2320-272-23-4
0746
REMOVAL - Continued
3 2 1
M5164DAA
Personnel Heater Hoses Removal.
0746-3
TM 9-2320-272-23-4
0746
INSTALLATION 1. 2. 3. Install heater inlet hose (Figure 2, Item 1) on elbow (Figure 2, Item 8) with clamp (Figure 2, Item 9). Install heater inlet hose (Figure 2, Item 1) on oil cooler shutoff valve (Figure 2, Item 3) with hose clamp (Figure 2, Item 2). Install heater inlet hose (Figure 2, Item 1) on heater (Figure 2, Item 7) with clamp (Figure 2, Item 5), screw (Figure 2, Item 4), and nut (Figure 2, Item 6).
3 2 1
M5165DAA
Figure 2. Personnel Heater Hoses Installation. END OF TASK
0746-4
TM 9-2320-272-23-4
0746
FOLLOW-ON MAINTENANCE 1. 2. 3. Fill cooling system to proper level and test antifreeze. (Volume 2, WP 0287) Install right fender splash shield. (WP 0575) Check heater for proper operation. (TM 9-2320-272-10)
0746-5/6 blank
TM 9-2320-272-23-4
0747
FIELD MAINTENANCE PERSONNEL HOT WATER HEATER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin (Volume 5, WP 0827, Table 1, Item 257) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Personnel heater inlet and outlet hoses removed. (WP 0746)
0747-1
TM 9-2320-272-23-4
0747
REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Remove screw (Figure 1, Item 3), sheet spring nut (Figure 1, Item 7), and clamp bracket (Figure 1, Item 4) from bracket (Figure 1, Item 6). Remove cotter pin (Figure 1, Item 30) from fresh air shutoff rod (Figure 1, Item 2). Discard cotter pin. Remove fresh air control cable (Figure 1, Item 5) and clip (Figure 1, Item 31) from fresh air shutoff rod (Figure 1, Item 2). Remove four screws (Figure 1, Item 35), washers (Figure 1, Item 34), and canister (Figure 1, Item 1) from personnel hot water heater (Figure 1, Item 21). Disconnect lead (Figure 1, Item 25) from heater blower motor lead (Figure 1, Item 26). Remove setscrew (Figure 1, Item 33) and fan/impeller (Figure 1, Item 32) from heater blower motor (Figure 1, Item 29). Remove four screws (Figure 1, Item 27), washers (Figure 1, Item 28), and heater blower motor (Figure 1, Item 29) from personnel hot water heater (Figure 1, Item 21). Remove nut (Figure 1, Item 19), washer (Figure 1, Item 13), screw (Figure 1, Item 10), and washer (Figure 1, Item 13) from rear heater support (Figure 1, Item 14). Remove nut (Figure 1, Item 24), washer (Figure 1, Item 15), screw (Figure 1, Item 12), and washer (Figure 1, Item 15) from forward heater support (Figure 1, Item 18). Remove four screws (Figure 1, Item 23) and washers (Figure 1, Item 22) from forward and rear heater supports (Figure 1, Item 18) and (Figure 1, Item 14). Remove two screws (Figure 1, Item 17), washers (Figure 1, Item 16), and left mounting bracket (Figure 1, Item 20) from firewall (Figure 1, Item 8).
CAUTION
Do not twist or bend elbows. They are welded to personnel hot water heater. 12. Remove personnel hot water heater (Figure 1, Item 21) from diverter duct (Figure 1, Item 9) and right mounting bracket (Figure 1, Item 11).
0747-2
TM 9-2320-272-23-4
0747
REMOVAL - Continued
1 2 35 34
3 4
33 5 6 7 7 9 8 31 29 28 21 27 15 30 12 11 13 14 10
21 32
26 15
18
16 25 24 23 22 20 13 19
M5166DAA
17
Figure 1. Personnel Hot Water Heater Removal. END OF TASK
0747-3
TM 9-2320-272-23-4
0747
INSTALLATION
CAUTION
During installation of personnel water heater, do not twist or bend elbows. They are welded and may be damaged. 1. 2. 3. 4. Position personnel hot water heater (Figure 2, Item 21) on diverter duct (Figure 2, Item 9) and right mounting bracket (Figure 2, Item 11). Install left mounting bracket (Figure 2, Item 20) on firewall (Figure 2, Item 8) with two washers (Figure 2, Item 16) and screws (Figure 2, Item 17). Install forward and rear supports (Figure 2, Item 18) and (Figure 2, Item 14) on personnel hot water heater (Figure 2, Item 21) with four washers (Figure 2, Item 22) and screws (Figure 2, Item 23). Install forward and rear supports (Figure 2, Item 18) and (Figure 2, Item 14) on left mounting bracket (Figure 2, Item 20) and right mounting bracket (Figure 2, Item 11) with washer (Figure 2, Item 15), screw (Figure 2, Item 12), washer (Figure 2, Item 15), nut (Figure 2, Item 24), washer (Figure 2, Item 13), screw (Figure 2, Item 10), washer (Figure 2, Item 13), and nut (Figure 2, Item 19). Install heater blower motor (Figure 2, Item 29) on personnel hot water heater (Figure 2, Item 21) with four washers (Figure 2, Item 28) and screws (Figure 2, Item 27). Install fan/impeller (Figure 2, Item 32) on heater blower motor (Figure 2, Item 29) with setscrew (Figure 2, Item 33). Connect lead (Figure 2, Item 25) to heater blower motor lead (Figure 2, Item 26). Install canister (Figure 2, Item 1) on personnel hot water heater (Figure 2, Item 21) with four washers (Figure 2, Item 34) and screws (Figure 2, Item 35). Install clip (Figure 2, Item 31) and fresh air control cable (Figure 2, Item 5) on fresh air shutoff rod (Figure 2, Item 2) with cotter pin (Figure 2, Item 30). Install clamp bracket (Figure 2, Item 4) and fresh air control cable (Figure 2, Item 5) on bracket (Figure 2, Item 6) with screw (Figure 2, Item 3) and spring nut (Figure 2, Item 7).
5. 6. 7. 8. 9. 10.
0747-4
TM 9-2320-272-23-4
0747
1 2 35 34
3 4
33 5 6 7 9 8 31 30 11 12 13 28 27 24 15 14 10
21 32 29
26
18
15 25 24 23 22 20 16 13 19 17
M5167DAA
Personnel Hot Water Heater Installation.
0747-5
TM 9-2320-272-23-4
0747
FOLLOW-ON MAINTENANCE 1. 2. Install personnel heater inlet and outlet hoses. (WP 0746) Check heater for proper operation. (TM 9-2320-272-10)
0747-6
TM 9-2320-272-23-4
0748
FIELD MAINTENANCE ENGINE COOLANT HEATER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin Materials/Parts (cont.) (Volume 5, WP 0827, Table 1, Item 348) Qty: 1 Locknut (Volume 5, WP 0827, Table 1, Item 285) Qty: 4 Equipment Condition Engine coolant heater pump removed. (WP 0752)
0748-1
TM 9-2320-272-23-4
0748
REMOVAL 1. Disconnect heater harness (Figure 1, Item 3) from engine coolant heater (Figure 1, Item 2).
NOTE
Have drainage container ready to catch excess fuel. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. 2. 3. 4. 5. 6. 7. 8. 9. Disconnect fuel line (Figure 1, Item 8) and elbow (Figure 1, Item 9) from engine coolant heater (Figure 1, Item 2). Disconnect hose (Figure 1, Item 7), adapter (Figure 1, Item 6), elbow (Figure 1, Item 5), union (Figure 1, Item 4), and nipple (Figure 1, Item 10) from engine coolant heater (Figure 1, Item 2). Remove cotter pin (Figure 1, Item 19) and exhaust tube (Figure 1, Item 18) from engine coolant heater (Figure 1, Item 2). Discard cotter pin. Remove hose (Figure 1, Item 13), adapter (Figure 1, Item 15), and elbow (Figure 1, Item 16) from engine coolant heater (Figure 1, Item 2). Remove two clamps (Figure 1, Item 11) from engine coolant heater (Figure 1, Item 2). Remove engine coolant heater (Figure 1, Item 2) from bracket (Figure 1, Item 12). Remove four locknuts (Figure 1, Item 17) and screws (Figure 1, Item 14) from bracket (Figure 1, Item 12). Discard locknuts. Remove bracket (Figure 1, Item 12) from toolbox (Figure 1, Item 1).
0748-2
TM 9-2320-272-23-4
0748
REMOVAL - Continued
5 3 4 6 7
2 1 9 10
11
12 19 13
18
14 15 17 16
M9733DAA
Engine Coolant Heater Removal.
0748-3
TM 9-2320-272-23-4
0748
INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. Install bracket (Figure 2, Item 12) on toolbox (Figure 2, Item 1). Install four screws (Figure 2, Item 14) and locknuts (Figure 2, Item 17) on bracket (Figure 2, Item 12). Install engine coolant heater (Figure 2, Item 2) on bracket (Figure 2, Item 12). Install two clamps (Figure 2, Item 11) on engine coolant heater (Figure 2, Item 2). Install elbow (Figure 2, Item 16), adapter (Figure 2, Item 15), and hose (Figure 2, Item 13) on engine coolant heater (Figure 2, Item 2). Install exhaust tube (Figure 2, Item 18) on engine coolant heater (Figure 2, Item 2) with cotter pin (Figure 2, Item 19). Install nipple (Figure 2, Item 10), union (Figure 2, Item 4), elbow (Figure 2, Item 5), adapter (Figure 2, Item 6), and hose (Figure 2, Item 7) on engine coolant heater (Figure 2, Item 2). Install elbow (Figure 2, Item 9) and fuel line (Figure 2, Item 8) on engine coolant heater (Figure 2, Item 2). Connect heater harness (Figure 2, Item 3) to engine coolant heater (Figure 2, Item 2).
0748-4
TM 9-2320-272-23-4
0748
5 3 4 6 7
2 1 9 10
11
12 19 13
18
14 15 17 16
M9734DAA
Engine Coolant Heater Installation.
Install engine coolant heater pump. (WP 0752) END OF TASK END OF WORK PACKAGE
0748-5/6 blank
TM 9-2320-272-23-4
0749
FIELD MAINTENANCE RADIATOR COVER KIT REPLACEMENT
REMOVAL 1. 2. Untie ends of tiedown strap (Figure 1, Item 5) and remove from 28 tiedown loops (Figure 1, Item 2). Remove radiator cover (Figure 1, Item 1), 56 screws (Figure 1, Item 3), and 28 tiedown loops (Figure 1, Item 2) from hood (Figure 1, Item 4).
1
2, 3
2 3
M9731DAA
Radiator Cover Kit Removal.
0749-1
TM 9-2320-272-23-4
0749
INSTALLATION 1. Install 28 tiedown loops (Figure 2, Item 2) on hood (Figure 2, Item 4) with 56 screws (Figure 2, Item 3).
NOTE
Raise hood for ease in tucking bottom flap between hood brackets. 2. 3. Position radiator cover (Figure 2, Item 1) on 28 tiedown loops (Figure 2, Item 2). Thread tiedown strap (Figure 2, Item 5) through 28 tiedown loops (Figure 2, Item 2) and tie ends together.
1
2, 3
2 3
M9732DAA
Radiator Cover Kit Installation.
0749-2
TM 9-2320-272-23-4
0750
FIELD MAINTENANCE HARDTOP KIT REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 314) Qty: 32 Lockwasher (Volume 5, WP 0827, Table 1, Item 392) Qty: 2 Rubber Seal (Volume 5, WP 0827, Table 1, Item 44) Qty: 2 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10)
0750-1
TM 9-2320-272-23-4
0750
REMOVAL
NOTE
Assistant will help when required. 1. Remove two screws (Figure 1, Item 1) and lockwashers (Figure 1, Item 16) from roof assembly (Figure 1, Item 2). Discard lockwashers.
NOTE
Note position of hook bolts for installation. 2. 3. 4. 5. Remove four nuts (Figure 1, Item 3) and hook bolts (Figure 1, Item 15) from top of roof assembly (Figure 1, Item 2) and windshield frame (Figure 1, Item 14). Remove 16 locknuts (Figure 1, Item 4), washers (Figure 1, Item 5), screws (Figure 1, Item 8), and washers (Figure 1, Item 5) from roof assembly (Figure 1, Item 2). Discard locknuts. Remove roof assembly (Figure 1, Item 2) and rubber seal (Figure 1, Item 6) from back panel assembly (Figure 1, Item 7) and windshield frame (Figure 1, Item 14). Discard rubber seal. Remove 16 locknuts (Figure 1, Item 10), screws (Figure 1, Item 9), washers (Figure 1, Item 13), back panel assembly (Figure 1, Item 7), and rubber seal (Figure 1, Item 12) from cab body (Figure 1, Item 11). Discard locknuts and rubber seals.
0750-2
TM 9-2320-272-23-4
0750
REMOVAL - Continued
3 4 5
16 15 14 6 7 5 7 9 13
12 11
10
M9729DAA
Hardtop Kit Removal.
0750-3
TM 9-2320-272-23-4
0750
INSTALLATION 1. Install rubber seal (Figure 2, Item 12) and back panel assembly (Figure 2, Item 7) on cab body (Figure 2, Item 11) with 16 washers (Figure 2, Item 13), screws (Figure 2, Item 9), and locknuts (Figure 2, Item 10). Do not tighten locknuts. Install rubber seal (Figure 2, Item 6) and roof assembly (Figure 2, Item 2) on back panel assembly (Figure 2, Item 7) with 16 washers (Figure 2, Item 5), screws (Figure 2, Item 8), washers (Figure 2, Item 5), and locknuts (Figure 2, Item 4). Do not tighten locknuts. Install roof assembly (Figure 2, Item 2) on windshield frame (Figure 2, Item 14) with four hook bolts (Figure 2, Item 15) and nuts (Figure 2, Item 3). Do not tighten nuts. Inspect all hardtop kit panels for alignment and seating. Adjust as required. Close cab windows and inspect for alignment with roof assembly (Figure 2, Item 2). Adjust as required. Tighten 16 locknuts (Figure 2, Items 4 and 10) and four nuts (Figure 2, Item 3). Install two lockwashers (Figure 2, Item 16) and screws (Figure 2, Item 1) on roof assembly (Figure 2, Item 2).
2.
3. 4. 5. 6. 7.
0750-4
TM 9-2320-272-23-4
0750
1 2 3 4 5
16 15 14 6 7 5 7 9 13 8
12 11
10
M9730DAA
Hardtop Kit Installation.
0750-5/6 blank
TM 9-2320-272-23-4
0751
FIELD MAINTENANCE PERSONNEL FUEL BURNING HEATER AND MOUNTING BRACKET REPLACEMENT (M939/A1)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin (Volume 5, WP 0827, Table 1, Item 351) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Hood raised and secured. (TM 9-2320-272-10)
0751-1
TM 9-2320-272-23-4
0751
REMOVAL
WARNING
Diesel fuel is flammable. Do not perform this procedure near open flames. Failure to comply may result in injury or death to personnel. 1. 2. 3. 4. 5. Disconnect heater harness (Figure 1, Item 2) from fuel burning heater (Figure 1, Item 1). Disconnect fuel line (Figure 1, Item 7) from heater elbow (Figure 1, Item 6). Remove cotter pin (Figure 1, Item 3) from exhaust tube (Figure 1, Item 4) and fuel burning heater (Figure 1, Item 1). Discard cotter pin. Loosen two clamps (Figure 1, Item 5) and remove fuel burning heater (Figure 1, Item 1) from clamps. Remove four screws (Figure 1, Item 11) and mounting brackets (Figure 1, Items 9 and 10) from firewall (Figure 1, Item 8).
6
1 5 2
7 8 9 10
3 4
11
M6145DAA
Personnel Fuel Burning Heater and Mounting Bracket Removal (M939/A1).
0751-2
TM 9-2320-272-23-4
0751
INSTALLATION 1. 2. 3. 4. 5. Install mounting brackets (Figure 2, Items 9 and 10) on firewall (Figure 2, Item 8) with four screws (Figure 2, Item 11). Install fuel burning heater (Figure 2, Item 1) into clamps (Figure 2, Item 5) and tighten clamps. Install exhaust tube (Figure 2, Item 4) on fuel burning heater (Figure 2, Item 1) with cotter pin (Figure 2, Item 3). Connect fuel line (Figure 2, Item 7) to heater elbow (Figure 2, Item 6). Connect heater harness (Figure 2, Item 2) to fuel burning heater (Figure 2, Item 1).
1 5 2
7 8 9 10
3 11 4
M6146DAA
Figure 2. Personnel Fuel Burning Heater and Mounting Bracket Installation (M939/A1). END OF TASK FOLLOW-ON MAINTENANCE Check personnel fuel burning heater for proper operation. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0751-3/4 blank
TM 9-2320-272-23-4
0752
FIELD MAINTENANCE ENGINE COOLANT HEATER PUMP REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Lockwasher (Volume 5, WP 0827, Table 1, Item 390) Qty: 2 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Hood raised and secured. (TM 9-2320-272-10)
0752-1
TM 9-2320-272-23-4
0752
REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Close water manifold drain valve (Figure 1, Item 1) and oil cooler drain valve (Figure 1, Item 2). Open toolbox door (Figure 1, Item 10). Close two engine coolant heater drain valves (Figure 1, Item 22). Loosen clamp (Figure 1, Item 19) and remove manifold inlet hose (Figure 1, Item 21) from heater pump elbow (Figure 1, Item 8). Loosen clamp (Figure 1, Item 20) and remove pump outlet hose (Figure 1, Item 23) from heater pump adapter (Figure 1, Item 14). Remove nut (Figure 1, Item 11) and lockwasher (Figure 1, Item 17) from terminal stud (Figure 1, Item 14) and disconnect ground wire (Figure 1, Item 13) from heater pump (Figure 1, Item 6). Discard lockwasher. Remove nut (Figure 1, Item 18) and lockwasher (Figure 1, Item 17) from terminal stud (Figure 1, Item 15) and disconnect wire (Figure 1, Item 16) from heater pump (Figure 1, Item 6). Discard lockwasher. Remove clamp (Figure 1, Item 4) and heater pump (Figure 1, Item 6) from pump bracket (Figure 1, Item 3). Remove heater pump elbow (Figure 1, Item 8) and adapter (Figure 1, Item 7) from heater pump. Remove heater pump adapter (Figure 1, Item 5) from port (Figure 1, Item 9).
0752-2
TM 9-2320-272-23-4
0752
REMOVAL - Continued
20
21
22
23
3 4 5
5 19 8 12 13 15 14 16 6 18 17
9 11 10 6 8
Engine Coolant Heater Pump Removal.
M9727DAA
0752-3
TM 9-2320-272-23-4
0752
INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Install heater pump adapter (Figure 2, Item 5) in port (Figure 2, Item 9). Install adapter (Figure 2, Item 7) and heater pump elbow (Figure 2, Item 8) in heater pump (Figure 2, Item 6). Install heater pump (Figure 2, Item 6) on pump bracket (Figure 2, Item 3) with clamp (Figure 2, Item 4). Install wire (Figure 2, Item 16) on terminal stud (Figure 2, Item 15) with lockwasher (Figure 2, Item 17) and nut (Figure 2, Item 18). Install ground wire (Figure 2, Item 13) on terminal stud (Figure 2, Item 14) with lockwasher (Figure 2, Item 12) and nut (Figure 2, Item 11). Install pump outlet hose (Figure 2, Item 23) on heater pump elbow (Figure 2, Item 5) and tighten clamp (Figure 2, Item 20). Install manifold inlet hose (Figure 2, Item 21) on heater pump elbow (Figure 2, Item 8) and tighten clamp (Figure 2, Item 19). Open two engine coolant heater drain valves (Figure 2, Item 22). Open water manifold drain valve (Figure 2, Item 1) and coolant outlet drain valve (Figure 2, Item 2). Close toolbox door (Figure 2, Item 10).
0752-4
TM 9-2320-272-23-4
0752
20
21
22
23 3 4 5
5 19 8 12 13 15 14 16 6 18 17
9 11 10 6 8 7
M9728DAA
Figure 2. Engine Coolant Heater Pump Installation. END OF TASK END OF WORK PACKAGE
0752-5/6 blank
TM 9-2320-272-23-4
0753
FIELD MAINTENANCE ENGINE COOLANT HEATER CONTROL BOX REPLACEMENT
0753-1
TM 9-2320-272-23-4
0753
REMOVAL 1. 2. 3. 4. Disconnect coolant heater harness connector (Figure 1, Item 5) from coolant heater control box (Figure 1, Item 8). Disconnect connector (Figure 1, Item 6) from control box wire (Figure 1, Item 7). Remove two nuts (Figure 1, Item 2), lockwashers (Figure 1, Item 3), and coolant heater control box (Figure 1, Item 8) from control mounting bracket (Figure 1, Item 4). Discard lockwashers. Remove two locknuts (Figure 1, Item 1), screws (Figure 1, Item 9), and control mounting bracket (Figure 1, Item 4) from instrument panel (Figure 1, Item 10). Discard locknuts.
1 10 2 3
8
M9725DAA
Engine Coolant Heater Control Box Removal.
0753-2
TM 9-2320-272-23-4
0753
INSTALLATION 1. 2. 3. 4. Install control mounting bracket (Figure 2, Item 4) on instrument panel (Figure 2, Item 10) with two screws (Figure 2, Item 9) and locknuts (Figure 2, Item 1). Install coolant heater control box (Figure 2, Item 8) on control mounting bracket (Figure 2, Item 4) with two lockwashers (Figure 2, Item 3) and nuts (Figure 2, Item 2). Connect connector (Figure 2, Item 6) to control box wire (Figure 2, Item 7). Connect coolant heater harness (Figure 2, Item 5) to coolant heater control box (Figure 2, Item 8).
1 10 2 3
8
M9726DAA
Figure 2. Engine Coolant Heater Control Box Installation. END OF TASK
0753-3
TM 9-2320-272-23-4
0753
FOLLOW-ON MAINTENANCE 1. 2. Connect battery ground cables. (Volume 2, WP 0350) Check engine coolant heater for proper operation. (TM 9-2320-272-10)
0753-4
TM 9-2320-272-23-4
0754
FIELD MAINTENANCE ENGINE COOLANT HEATER HARNESS REPLACEMENT (M939/A1)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Lockwasher (Volume 5, WP 0827, Table 1, Item 403) Qty: 2 Tiedown Strap (Volume 5, WP 0827, Table 1, Item 375) Qty: 10 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Hood raised and secured. (TM 9-2320-272-10) Battery ground cables disconnected. (Volume 2, WP 0350)
0754-1
TM 9-2320-272-23-4
0754
REMOVAL 1. 2. 3. 4. 5. 6. 7. Open toolbox door (Figure 1, Item 9). Disconnect engine coolant heater harness (Figure 1, Item 2) from engine coolant heater (Figure 1, Item 20). Remove nut (Figure 1, Item 10), lockwasher (Figure 1, Item 11), and ground wire (Figure 1, Item 12) from terminal stud (Figure 1, Item 13) on heater pump (Figure 1, Item 18). Discard lockwasher. Remove nut (Figure 1, Item 17), lockwasher (Figure 1, Item 16), and ground wire (Figure 1, Item 15) from terminal stud (Figure 1, Item 14) on heater pump (Figure 1, Item 18). Discard lockwasher. Remove ten tiedown straps (Figure 1, Item 5) from engine coolant heater harness (Figure 1, Item 2), fuel pump cable (Figure 1, Item 6), hose (Figure 1, Item 7), and lead (Figure 1, Item 22). Discard tiedown straps. Disconnect lead (Figure 1, Item 22) from engine coolant heater harness lead (Figure 1, Item 4). Disconnect engine coolant heater harness (Figure 1, Item 2) from control box (Figure 1, Item 1), slide through grommet (Figure 1, Item 3) in firewall (Figure 1, Item 21) and grommet (Figure 1, Item 8) in toolbox (Figure 1, Item 19), and remove from vehicle.
0754-2
TM 9-2320-272-23-4
0754
REMOVAL - Continued
2 3
4 22 21 5
6 2 7 5 20 19 11 18 12 17 16 13 15 14
M9647DAA
8 9 10
Figure 1. Engine Coolant Heater Harness Removal. END OF TASK
0754-3
TM 9-2320-272-23-4
0754
INSTALLATION 1. Slide engine coolant heater harness (Figure 2, Item 2) through grommet (Figure 2, Item 8) in toolbox (Figure 2, Item 19) and grommet (Figure 2, Item 3) in firewall (Figure 2, Item 21) and connect to control box (Figure 2, Item 1). Connect lead (Figure 2, Item 22) to engine coolant heater harness lead (Figure 2, Item 4). Install ten tiedown straps (Figure 2, Item 5) on engine coolant heater harness (Figure 2, Item 2), fuel pump cable (Figure 2, Item 6), hose (Figure 2, Item 7), and lead (Figure 2, Item 22). Connect ground wire (Figure 2, Item 15) to terminal stud (Figure 2, Item 14) on heater pump (Figure 2, Item 18) with lockwasher (Figure 2, Item 16) and nut (Figure 2, Item 17). Connect ground wire (Figure 2, Item 12) to terminal stud (Figure 2, Item 13) on heater pump (Figure 2, Item 18) with lockwasher (Figure 2, Item 11) and nut (Figure 2, Item 10). Connect engine coolant heater harness (Figure 2, Item 2) to engine coolant heater (Figure 2, Item 20). Close toolbox door (Figure 2, Item 9).
2. 3. 4. 5. 6. 7.
0754-4
TM 9-2320-272-23-4
0754
2 3
4 22 21 5
6 2 7 5 20 19 11 18 12 17 16 13 15 14
M9648DAA
8 9 10
Figure 2. Engine Coolant Heater Harness Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Connect battery ground cables. (Volume 2, WP 0350) Check engine coolant heater for proper operation. (TM 9-2320-272-10)
0754-5/6 blank
TM 9-2320-272-23-4
0755
FIELD MAINTENANCE ENGINE COOLANT HEATER HARNESS REPLACEMENT (M939/A2)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Lockwasher (Volume 5, WP 0827, Table 1, Item 403) Qty: 2 Tiedown Strap (Volume 5, WP 0827, Table 1, Item 375) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Battery ground cables disconnected. (Volume 2, WP 0350)
0755-1
TM 9-2320-272-23-4
0755
REMOVAL 1. 2. 3. 4. 5. 6. 7. Open toolbox door (Figure 1, Item 12). Disconnect engine coolant heater harness (Figure 1, Item 3) from engine coolant heater (Figure 1, Item 22). Remove nut (Figure 1, Item 13), lockwasher (Figure 1, Item 14), and ground wire (Figure 1, Item 21) from terminal stud (Figure 1, Item 15) on heater pump (Figure 1, Item 19). Discard lockwasher. Remove nut (Figure 1, Item 18), lockwasher (Figure 1, Item 20), and wire (Figure 1, Item 17) from terminal stud (Figure 1, Item 16) on heater pump (Figure 1, Item 19). Discard lockwasher. Remove screw (Figure 1, Item 7), nut (Figure 1, Item 6), and clamp (Figure 1, Item 8) from bracket (Figure 1, Item 9). Remove tiedown strap (Figure 1, Item 5) from engine coolant heater harness (Figure 1, Item 3). Discard tiedown strap. Disconnect engine coolant heater harness (Figure 1, Item 3) from control box (Figure 1, Item 1) and slide harness through grommet (Figure 1, Item 4) in firewall (Figure 1, Item 2) and grommet (Figure 1, Item 10) in toolbox (Figure 1, Item 11).
0755-2
TM 9-2320-272-23-4
0755
REMOVAL - Continued
1 2 3 4
6 7 3 10 9 21 20 22 13 19 18 17 16 15
M9642DAA
11 12
14
Figure 1. Engine Coolant Heater Harness Removal. END OF TASK
0755-3
TM 9-2320-272-23-4
0755
INSTALLATION 1. Slide engine coolant heater harness (Figure 2, Item 3) through grommet (Figure 2, Item 4) in firewall (Figure 2, Item 2) and grommet (Figure 2, Item 10) in toolbox (Figure 2, Item 11) and connect to control box (Figure 2, Item 1). Install tiedown strap (Figure 2, Item 5) on engine coolant heater harness (Figure 2, Item 3). Install engine coolant heater harness (Figure 2, Item 3) on bracket (Figure 2, Item 9) with clamp (Figure 2, Item 8), screw (Figure 2, Item 7), and nut (Figure 2, Item 6). Connect engine coolant heater harness (Figure 2, Item 3) to engine coolant heater (Figure 2, Item 22). Install wire (Figure 2, Item 17) on terminal stud (Figure 2, Item 16) with lockwasher (Figure 2, Item 20) and nut (Figure 2, Item 18). Install ground wire (Figure 2, Item 21) on terminal stud (Figure 2, Item 15) with lockwasher (Figure 2, Item 14) and nut (Figure 2, Item 13). Close toolbox door (Figure 2, Item 12).
2. 3. 4. 5. 6. 7.
0755-4
TM 9-2320-272-23-4
0755
1 2 3 4
6 7 3 10 9 21 20 22 19 18 17 16 15
M9643DAA
11 12 13 14
Figure 2. Engine Coolant Heater Harness Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Connect battery ground cables. (Volume 2, WP 0350) Check engine coolant heater for proper operation. (TM 9-2320-272-10)
0755-5/6 blank
TM 9-2320-272-23-4
0756
FIELD MAINTENANCE ENGINE COOLANT OIL PAN SHROUD AND EXHAUST TUBE REPLACEMENT
0756-1
TM 9-2320-272-23-4
0756
REMOVAL 1. 2. 3. 4. 5. Remove two locknuts (Figure 1, Item 4), screws (Figure 1, Item 10), and clamps (Figure 1, Item 9) from exhaust tube (Figure 1, Item 13), crossmember (Figure 1, Item 11), and bracket (Figure 1, Item 12). Discard locknuts. Open toolbox door (Figure 1, Item 1). Remove two cotter pins (Figure 1, Item 3), exhaust tube (Figure 1, Item 13), and elbow (Figure 1, Item 14) from engine coolant heater (Figure 1, Item 2) and oil pan shroud (Figure 1, Item 6). Discard cotter pins. Remove cotter pin (Figure 1, Item 3) and elbow (Figure 1, Item 14) from exhaust tube (Figure 1, Item 13). Discard cotter pin. Remove four nuts (Figure 1, Item 8), washers (Figure 1, Item 7), and oil pan shroud (Figure 1, Item 6) from oil pan studs (Figure 1, Item 5).
1 2
3 4 5
7 4 14 13 10
Figure 1. Engine Coolant Oil Pan Shroud and Exhaust Tube Removal. END OF TASK
9 11 10
12 9
M10012DAA
0756-2
TM 9-2320-272-23-4
0756
INSTALLATION 1. 2. 3. 4. 5. Install oil pan shroud (Figure 2, Item 6) on oil pan studs (Figure 2, Item 5) with four washers (Figure 2, Item 7) and nuts (Figure 2, Item 8). Install elbow (Figure 2, Item 14) on exhaust tube (Figure 2, Item 13) with cotter pin (Figure 2, Item 3). Install exhaust tube (Figure 2, Item 13) and elbow (Figure 2, Item 14) on engine coolant heater (Figure 2, Item 2) and oil pan shroud (Figure 2, Item 6) with two cotter pins (Figure 2, Item 3). Close toolbox door (Figure 2, Item 1). Install exhaust tube (Figure 2, Item 13) on crossmember (Figure 2, Item 11) and bracket (Figure 2, Item 12) with two clamps (Figure 2, Item 9), screws (Figure 2, Item 10), and locknuts (Figure 2, Item 4).
1 2
3 4 5
7 4 14 13 10
Figure 2. Engine Coolant Oil Pan Shroud and Exhaust Tube Installation. END OF TASK END OF WORK PACKAGE
9 11 10
12 9
M10013DAA
0756-3/4 blank
TM 9-2320-272-23-4
0757
FIELD MAINTENANCE ENGINE COOLANT HEATER HOSE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Lockwasher (Volume 5, WP 0827, Table 1, Item 186) Qty: 1 Tiedown Strap (Volume 5, WP 0827, Table 1, Item 375) Qty: 9 References Volume 2, WP 0287 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Hood raised and secured. (TM 9-2320-272-10) Right side splash shield removed. (TM 9-2320-272-10)
0757-1
TM 9-2320-272-23-4
0757
REMOVAL 1. 2. Close water manifold drain valve (Figure 1, Item 1) on right side of engine (Figure 1, Item 3). Close coolant outlet drain valve (Figure 1, Item 2) on right side of engine (Figure 1, Item 3).
NOTE
Have drainage container ready to catch excess coolant. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. 3. 4. Loosen clamp (Figure 1, Item 27) and remove hose (Figure 1, Item 20) from water manifold drain valve (Figure 1, Item 1). Remove nut (Figure 1, Item 10), lockwasher (Figure 1, Item 9), clamps (Figure 1, Items 12 and 24), washer (Figure 1, Item 22), and screw (Figure 1, Item 23) from oil dipstick tube bracket (Figure 1, Item 8) and oil dipstick tube (Figure 1, Item 11). Discard lockwasher. Remove screw (Figure 1, Item 18) and clamp (Figure 1, Item 19) from cab support (Figure 1, Item 13). Remove three tiedown straps (Figure 1, Item 21) from hose (Figure 1, Item 20), fuel line (Figure 1, Item 26), and electrical harness (Figure 1, Item 25). Discard tiedown straps. Loosen clamp (Figure 1, Item 7) and remove hose (Figure 1, Item 6) from coolant outlet drain valve (Figure 1, Item 2). Remove screw (Figure 1, Item 16), washer (Figure 1, Item 15), and clamp (Figure 1, Item 14) from engine access cover (Figure 1, Item 5). Remove two tiedown straps (Figure 1, Item 17) from hose (Figure 1, Item 6) and two transmission oil cooler lines (Figure 1, Item 4). Discard tiedown straps.
5. 6. 7. 8. 9.
0757-2
TM 9-2320-272-23-4
0757
REMOVAL - Continued
1 27 26
24 23 22
25
8 9 10 2 12 11 6 7
21
13
20 19 18 17 3
16
15
14
5 4
M9902DAA
Figure 1. Engine Coolant Heater Hose Removal.
0757-3
TM 9-2320-272-23-4
0757
REMOVAL - Continued 10. 11. Remove two tiedown straps (Figure 2, Item 3) from hose (Figure 2, Item 7), fuel line (Figure 2, Item 14), and electrical harness (Figure 2, Item 13). Discard tiedown straps. Remove screw (Figure 2, Item 8), clamp (Figure 2, Item 5), and hose (Figure 2, Item 7) from crossmember (Figure 2, Item 6).
NOTE
Note routing of hose for installation. 12. 13. 14. 15. 16. 17. Loosen clamp (Figure 2, Item 12) and remove hose (Figure 2, Item 7) from coolant heater (Figure 2, Item 15), adapter (Figure 2, Item 11), and vehicle. Remove nut (Figure 2, Item 4), screw (Figure 2, Item 10), clamp (Figure 2, Item 2), and hose (Figure 2, Item 1) from air tank bracket (Figure 2, Item 9). Remove two tiedown straps (Figure 2, Item 24) from hose (Figure 2, Item 1) and electrical harness (Figure 2, Item 25). Discard tiedown straps. Loosen clamp (Figure 2, Item 23) and remove hose (Figure 2, Item 1) from adapter (Figure 2, Item 22) on coolant heater pump (Figure 2, Item 21). Loosen clamp (Figure 2, Item 19) and remove hose (Figure 2, Item 17) from adapter (Figure 2, Item 20) on coolant heater pump (Figure 2, Item 21). Loosen clamp (Figure 2, Item 18) and remove hose (Figure 2, Item 17) from adapter (Figure 2, Item 16) on coolant heater (Figure 2, Item 15).
0757-4
TM 9-2320-272-23-4
0757
REMOVAL - Continued
1 2
3 4 5
25 24 11 23 7 9 10
6 7
22
12
13 14 15
21 20 19 18 17
16 8
M9903DAA
Figure 2. Engine Coolant Heater Hose Removal.
0757-5
TM 9-2320-272-23-4
0757
REMOVAL - Continued 18. 19. Loosen clamp (Figure 3, Item 6) and remove hose (Figure 3, Item 1) from adapter (Figure 3, Item 2) and vehicle. Loosen clamp (Figure 3, Item 5) and remove hose (Figure 3, Item 4) from nipple (Figure 3, Item 3) and vehicle.
2 1
5 4
M9904DAA
Figure 3. Engine Coolant Heater Hose Removal. END OF TASK
0757-6
TM 9-2320-272-23-4
0757
INSTALLATION 1. 2. Route hose (Figure 4, Item 5) into position on vehicle and install hose on nipple (Figure 4, Item 4) and tighten clamp (Figure 4, Item 6). Route hose (Figure 4, Item 1) into position on vehicle and install hose on adapter (Figure 4, Item 3) and tighten clamp (Figure 4, Item 2).
6 5
M9905DAA
Figure 4. Engine Coolant Heater Hose Installation.
0757-7
TM 9-2320-272-23-4
0757
INSTALLATION - Continued 3. 4. 5. 6. 7. 8. 9. 10. Install hose (Figure 5, Item 17) on adapter (Figure 5, Item 16) and tighten clamp (Figure 5, Item 18). Install hose (Figure 5, Item 17) on adapter (Figure 5, Item 20) and tighten clamp (Figure 5, Item 19). Install hose (Figure 3, Item 1) on adapter (Figure 5, Item 22) and tighten clamp (Figure 5, Item 23). Install two tiedown straps (Figure 5, Item 24) on hose (Figure 5, Item 1) and electrical harness (Figure 5, Item 25). Install hose (Figure 5, Item 1) on air tank bracket (Figure 5, Item 9) with clamp (Figure 5, Item 2), screw (Figure 5, Item 10), and nut (Figure 5, Item 4). Route hose (Figure 5, Item 7) into position on vehicle and install hose and adapter (Figure 5, Item 11) on coolant heater (Figure 5, Item 15) and tighten clamp (Figure 5, Item 12). Install hose (Figure 5, Item 7) on crossmember (Figure 5, Item 6) with clamp (Figure 5, Item 5) and screw (Figure 5, Item 8). Install two tiedown straps (Figure 5, Item 3) on hose (Figure 5, Item 7), fuel line (Figure 5, Item 14), and electrical harness (Figure 5, Item 13).
0757-8
TM 9-2320-272-23-4
0757
1 3 2 4 5 10 11 23 7 9 7 6
25 24
22 21 12 13 14 15
16 20 19 18 17
M9906DAA
Figure 5. Hoses and Electrical Harness Installation.
0757-9
TM 9-2320-272-23-4
0757
INSTALLATION - Continued 11. 12. 13. 14. 15. 16. Install two tiedown straps (Figure 6, Item 17) on hose (Figure 6, Item 7) and two transmission oil cooler lines (Figure 6, Item 5). Install hose (Figure 6, Item 7) on engine access cover (Figure 6, Item 6) with clamp (Figure 6, Item 14), washer (Figure 6, Item 15), and screw (Figure 6, Item 16). Install hose (Figure 6, Item 7) on coolant outlet drain valve (Figure 6, Item 3) and tighten clamp (Figure 6, Item 8). Install three tiedown straps (Figure 6, Item 22) on hose (Figure 6, Item 21), fuel line (Figure 6, Item 27), and electrical harness (Figure 6, Item 26). Install hose (Figure 6, Item 21) on cab support (Figure 6, Item 18), clamp (Figure 6, Item 20), and screw (Figure 6, Item 19). Install hose (Figure 6, Item 21) and oil dipstick tube (Figure 6, Item 13) on oil dipstick tube bracket (Figure 6, Item 9) with clamps (Figure 6, Item 23) and (Figure 6, Item 10), washer (Figure 6, Item 24), screw (Figure 6, Item 25), lockwasher (Figure 6, Item 12), and nut (Figure 6, Item 11). Install hose (Figure 6, Item 21) on water manifold drain valve (Figure 6, Item 2) and tighten clamp (Figure 6, Item 1). Open coolant outlet drain valve (Figure 6, Item 2) on right side of engine (Figure 6, Item 4). Open water manifold drain valve (Figure 6, Item 3) on right side of engine (Figure 6, Item 4).
17. 18. 19.
0757-10
TM 9-2320-272-23-4
0757
2 1 27
26
25 24 23 22 13 21 20 19 18 17 4 12 10 9 3
11 7
16
15
14
6 5
M9907DAA
Figure 6. Engine Coolant Heater Hose Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Fill coolant to proper level. (Volume 2, WP 0287) Start engine and check hose connections for leaks. (TM 9-2320-272-10) Install right splash shield. (TM 9-2320-272-10)
0757-11/12 blank
TM 9-2320-272-23-4
0758
FIELD MAINTENANCE ENGINE COOLANT BATTERY BOX HEATER PAD REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Tape, Antiseizing (Volume 5, WP 0825, Table 1, Item 65) Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Batteries removed. (Volume 2, WP 0350)
0758-1
TM 9-2320-272-23-4
0758
REMOVAL 1. 2. Loosen two hose clamps (Figure 1, Item 3) and remove inlet hose (Figure 1, Item 5) and outlet hose (Figure 1, Item 4) from engine coolant heater pad (Figure 1, Item 1) and adapter (Figure 1, Item 6). Remove adapter (Figure 1, Item 6) from elbow (Figure 1, Item 7).
NOTE
Mark position of elbow for installation. 3. 4. Remove elbow (Figure 1, Item 7) and nipple (Figure 1, Item 12) from heater pad (Figure 1, Item 1) at floor panel (Figure 1, Item 8). Remove heater pad (Figure 1, Item 1), two blocks (Figure 1, Item 10), four blocks (Figure 1, Item 9), and two blocks (Figure 1, Item 11) from battery box (Figure 1, Item 2).
0758-2
TM 9-2320-272-23-4
0758
REMOVAL - Continued
12
11 9 10 2
3 3 4
M10014DAA
Engine Coolant Battery Box Heater Pad Removal.
0758-3
TM 9-2320-272-23-4
0758
INSTALLATION
NOTE
Wrap all male pipe threads with antiseize tape before installation. 1. 2. 3. 4. Position two blocks (Figure 2, Item 11), four blocks (Figure 2, Item 9), two blocks (Figure 2, Item 10), and heater pad (Figure 2, Item 1) in battery box (Figure 2, Item 2). Install nipple (Figure 2, Item 12) and elbow (Figure 2, Item 7) on heater pad (Figure 2, Item 1) at floor panel (Figure 2, Item 8). Install adapter (Figure 2, Item 6) on elbow (Figure 2, Item 7). Install inlet hose (Figure 2, Item 5) and outlet hose (Figure 2, Item 4) on engine coolant heater pad (Figure 2, Item 1) and adapter (Figure 2, Item 6) and tighten two hose clamps (Figure 2, Item 3).
0758-4
TM 9-2320-272-23-4
0758
12
11 9 10 2
3 3 4
M10015DAA
Figure 2. Engine Coolant Battery Box Heater Pad Installation. END OF TASK
0758-5
TM 9-2320-272-23-4
0758
FOLLOW-ON MAINTENANCE Install batteries. (Volume 2, WP 0350) END OF TASK END OF WORK PACKAGE
0758-6
TM 9-2320-272-23-4
0759
FIELD MAINTENANCE PERSONNEL FUEL BURNING HEATER CONTROL BOX REPLACEMENT
0759-1
TM 9-2320-272-23-4
0759
REMOVAL 1. 2. 3. 4. Disconnect heater harness (Figure 1, Item 4) from heater control box (Figure 1, Item 7). Disconnect connector (Figure 1, Item 5) from control box wire (Figure 1, Item 6) on heater control box (Figure 1, Item 7). Remove two nuts (Figure 1, Item 2) and lockwashers (Figure 1, Item 3) from studs (Figure 1, Item 8) and remove coolant heater box (Figure 1, Item 7) from mounting bracket (Figure 1, Item 10). Discard lockwashers. Remove two locknuts (Figure 1, Item 1), screws (Figure 1, Item 9), and mounting bracket (Figure 1, Item 10) from underside of dash (Figure 1, Item 11). Discard locknuts.
2 11 3 4
10
6 7
M6143DAA
Personnel Fuel Burning Heater Control Box Removal.
0759-2
TM 9-2320-272-23-4
0759
INSTALLATION 1. 2. 3. 4. Install mounting bracket (Figure 2, Item 10) on underside of dash (Figure 2, Item 11) with two screws (Figure 2, Item 9) and locknuts (Figure 2, Item 1). Install heater control box (Figure 2, Item 7) on mounting bracket (Figure 2, Item 10) with two lockwashers (Figure 2, Item 3) and nuts (Figure 2, Item 2). Connect connector (Figure 2, Item 5) to control box wire (Figure 2, Item 6) on heater control box (Figure 2, Item 7). Connect heater harness (Figure 2, Item 4) to heater control box (Figure 2, Item 7).
2 11 3 4
10
6 7
M6144DAA
Figure 2. Personnel Fuel Burning Heater Control Box Installation. END OF TASK
0759-3
TM 9-2320-272-23-4
0759
FOLLOW-ON MAINTENANCE 1. 2. Connect battery ground cables. (Volume 2, WP 0350) Check personnel fuel burning heater for proper operation. (TM 9-2320-272-10)
0759-4
TM 9-2320-272-23-4
0760
FIELD MAINTENANCE PERSONNEL FUEL BURNING HEATER AND MOUNTING BRACKETS REPLACEMENT (M939A2)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Tape, Antiseizing (Volume 5, WP Cotter Pin (Volume 5, WP Qty: 1 Locknut (Volume 5, WP Qty: 4 Lockwasher (Volume 5, WP Qty: 1 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Hood raised and secured. (TM 9-2320-272-10) Fuel shutoff valve closed. (TM 9-2320-272-10) Battery ground cables disconnected. (Volume 2, WP 0350)
0825, Table 1, Item 65) 0827, Table 1, Item 350)
0827, Table 1, Item 283)
0827, Table 1, Item 422)
0760-1
TM 9-2320-272-23-4
0760
REMOVAL
WARNING
Diesel fuel is flammable. Do not perform this procedure near open flames. Failure to comply may result in injury or death to personnel. 1. 2. 3. 4. 5. 6. Disconnect heater harness (Figure 1, Item 12) from heater (Figure 1, Item 1). Disconnect hose (Figure 1, Item 4) from adapter (Figure 1, Item 3). Remove adapter (Figure 1, Item 3) from heater (Figure 1, Item 1). Remove cotter pin (Figure 1, Item 9) from elbow (Figure 1, Item 10) and exhaust port (Figure 1, Item 13). Discard cotter pin. Remove two clamps (Figure 1, Item 2) and heater (Figure 1, Item 1) from bracket (Figure 1, Item 8). Remove four locknuts (Figure 1, Item 7), washers (Figure 1, Item 6), screws (Figure 1, Item 5), two brackets (Figure 1, Item 8), lockwasher (Figure 1, Item 15), and ground wire (Figure 1, Item 14) from two mounting brackets (Figure 1, Item 11). Discard lockwasher and locknuts.
0760-2
TM 9-2320-272-23-4
0760
REMOVAL - Continued
1
2 13 5 3 11 14 15 6 11 6 6 7 10 9 8 7 6 12
4 5
M6147DAA
Personnel Fuel Burning Heater and Mounting Brackets Removal.
0760-3
TM 9-2320-272-23-4
0760
INSTALLATION
NOTE
Clean all male pipe and hose threads and wrap with antiseize tape before installation. 1. Install two brackets (Figure 2, Item 8) on two mounting brackets (Figure 2, Item 11) with five washers (Figure 2, Item 6), lockwasher (Figure 2, Item 15), ground wire (Figure 2, Item 14), four screws (Figure 2, Item 5), and locknuts (Figure 2, Item 7). Install heater (Figure 2, Item 1) on bracket (Figure 2, Items 8) with two clamps (Figure 2, Item 2). Install cotter pin (Figure 2, Item 9) on elbow (Figure 2, Item 10) and exhaust port (Figure 2, Item 13). Install adapter (Figure 2, Item 3) on heater (Figure 2, Item 1). Connect hose (Figure 2, Item 4) to adapter (Figure 2, Item 3). Connect heater harness (Figure 2, Item 12) to fuel burning heater (Figure 2, Item 1).
1
2. 3. 4. 5. 6.
2 13 5 3 11 14 15 6 11 6 6 7 10 9 8 7 6 12
4 5
M6148DAA
Personnel Fuel Burning Heater and Mounting Brackets Installation.
0760-4
TM 9-2320-272-23-4
0760
FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery ground cables. (Volume 2, WP 0350) Open fuel shutoff valve. (TM 9-2320-272-10) Check personnel fuel burning heater for proper operation. (TM 9-2320-272-10)
0760-5/6 blank
TM 9-2320-272-23-4
0761
FIELD MAINTENANCE PERSONNEL FUEL BURNING HEATER FUEL PUMP REPLACEMENT (M939/A1)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Tape, Antiseizing Materials/Parts (cont.) (Volume 5, WP 0825, Table 1, Item 65) Locknut (Volume 5, WP 0827, Table 1, Item 282) Qty: 2 Equipment Condition Parking brake set. (TM 9-2320-272-10) Battery ground cables disconnected. (Volume 2, WP 0350)
0761-1
TM 9-2320-272-23-4
0761
REMOVAL
WARNING
Diesel fuel is flammable. Do not perform this procedure near open flames. Failure to comply may result in injury or death to personnel. 1. Disconnect wire (Figure 1, Item 16) from wire (Figure 1, Item 17) on electrical wire clip (Figure 1, Item 15).
CAUTION
Cover or plug all openings after disconnecting lines and hoses to prevent contamination. Failure to do this may result in fuel pump damage.
NOTE
Tag hoses for installation. 2. 3. 4. 5. Disconnect hose (Figure 1, Item 5) from adapter (Figure 1, Item 4). Disconnect hose (Figure 1, Item 6) from adapter (Figure 1, Item 7). Remove locknut (Figure 1, Item 11) and screw (Figure 1, Item 1) from left-hand splash panel (Figure 1, Item 12) and fuel pump mounting bracket (Figure 1, Item 10). Discard locknut. Remove locknut (Figure 1, Item 11), screw (Figure 1, Item 1), fuel pump (Figure 1, Item 9), washer (Figure 1, Item 14), wire clip (Figure 1, Item 15), and washer (Figure 1, Item 13) from left-hand splash panel (Figure 1, Item 12). Discard locknut. Remove adapter (Figure 1, Item 7) from elbow (Figure 1, Item 8). Remove adapter (Figure 1, Item 4) from fuel shutoff valve (Figure 1, Item 3). Remove fuel shutoff valve (Figure 1, Item 3) from elbow (Figure 1, Item 2). Remove elbows (Figure 1, Items 2 and 8) from fuel pump (Figure 1, Item 9).
6. 7. 8. 9.
0761-2
TM 9-2320-272-23-4
0761
REMOVAL - Continued
1 14 10 13
15 16 11 12 17
2 3 4
12
8 5
11 10 7 9
M6149DAA
Figure 1. Personnel Fuel Burning Heater Fuel Pump Removal. END OF TASK
0761-3
TM 9-2320-272-23-4
0761
INSTALLATION
NOTE
Clean all male pipe threads and wrap with antiseize tape before installation. 1. 2. 3. 4. 5. Install elbows (Figure 2, Items 2 and 8) on fuel pump (Figure 2, Item 9). Install fuel shutoff valve (Figure 2, Item 3) on elbow (Figure 2, Item 2). Install adapter (Figure 2, Item 4) on fuel shutoff valve (Figure 2, Item 3). Install adapter (Figure 2, Item 7) on elbow (Figure 2, Item 8). Install fuel pump (Figure 2, Item 9) on left-hand splash panel (Figure 2, Item 12) with washer (Figure 2, Item 13), electrical wire clip (Figure 2, Item 15), washer (Figure 2, Item 14), screw (Figure 2, Item 1), and locknut (Figure 2, Item 11). Install screw (Figure 2, Item 1) and locknut (Figure 2, Item 11) on left-hand splash panel (Figure 2, Item 12) and fuel pump mounting bracket (Figure 2, Item 10). Connect hose (Figure 2, Item 6) to adapter (Figure 2, Item 7). Connect hose (Figure 2, Item 5) to adapter (Figure 2, Item 4). Connect wire (Figure 2, Item 16) to wire (Figure 2, Item 17) on wire clip (Figure 2, Item 15).
6. 7. 8. 9.
0761-4
TM 9-2320-272-23-4
0761
1 14 10 13
15 16 11 12 17
2 3 4
12
8 5
11 10 7 9
M6150DAA
Figure 2. Personnel Fuel Burning Heater Fuel Pump Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Connect battery ground cables. (Volume 2, WP 0350) Check personnel fuel burning heater for proper operation. (TM 9-2320-272-10)
0761-5/6 blank
TM 9-2320-272-23-4
0762
FIELD MAINTENANCE PERSONNEL FUEL BURNING HEATER ELECTRIC FUEL PUMP REPLACEMENT (M939A2)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Qty: 1 Locknut (Volume 5, WP 0827, Table 1, Item 282) Qty: 2 Equipment Condition Parking brake set. (TM 9-2320-272-10) Battery ground cables disconnected. (Volume 2, WP 0350)
0762-1
TM 9-2320-272-23-4
0762
REMOVAL
WARNING
Diesel fuel is flammable. Do not perform this procedure near open flames. Failure to comply may result in injury or death to personnel.
NOTE
Procedures for changing personnel fuel burning and engine coolant heater electric fuel pumps are similar, this procedure is for personnel fuel burning heater electric fuel pump. 1. Disconnect connector (Figure 1, Item 2) from electric fuel pump wire (Figure 1, Item 5).
CAUTION
When disconnecting lines and hoses from pump, immediately plug all open ports. Failure to comply can cause damage to pump.
NOTE
Tag all lines and ports for installation. Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills and leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. 2. 3. Disconnect fuel inlet line (Figure 1, Item 7) and outlet line (Figure 1, Item 1) from adapter fittings (Figure 1, Item 3). Remove two screws (Figure 1, Item 4), locknuts (Figure 1, Item 9), and electric fuel pump (Figure 1, Item 6) from left-hand splash panel (Figure 1, Item 8). Discard locknuts.
0762-2
TM 9-2320-272-23-4
0762
REMOVAL - Continued
1 9 8
4 7
3 6
M6151DAA
Figure 1. Personnel Fuel Burning Heater Electric Fuel Pump Removal. END OF TASK
0762-3
TM 9-2320-272-23-4
0762
INSTALLATION 1. 2. 3. Install electric fuel pump (Figure 2, Item 6) on left-hand splash panel (Figure 2, Item 8) with two screws (Figure 2, Item 4) and locknuts (Figure 2, Item 9). Connect fuel inlet line (Figure 2, Item 7) and outlet line (Figure 2, Item 1) to adapter fittings (Figure 2, Item 3). Connect connector (Figure 2, Item 2) to electric fuel pump wire (Figure 2, Item 5).
1 9 8
4 7
3 6
M6152DAA
Personnel Fuel Burning Heater Electric Fuel Pump Installation.
0762-4
TM 9-2320-272-23-4
0762
FOLLOW-ON MAINTENANCE 1. 2. Connect battery ground cables. (Volume 2, WP 0350) Check personnel fuel burning heater for proper operation. (TM 9-2320-272-10)
0762-5/6 blank
TM 9-2320-272-23-4
0763
FIELD MAINTENANCE PERSONNEL FUEL BURNING HEATER FUEL SHUTOFF VALVE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 5, WP 0825, Table 1, Item 13) Qty: 1 Tape, Antiseizing (Volume 5, WP 0825, Table 1, Item 65) Equipment Condition Parking brake set. (TM 9-2320-272-10)
0763-1
TM 9-2320-272-23-4
0763
REMOVAL
WARNING
Diesel fuel is flammable. Do not perform this procedure near open flames. Failure to comply may result in injury or death to personnel.
CAUTION
Cover or plug all openings after disconnecting lines and hoses to prevent contamination. Failure to comply may result in fuel pump damage.
NOTE
Use drain pans to retain leaking/draining fluids. Refer to local procedures and plans for preventing and responding to fluid spills and leaks. Comply with local regulations when disposing of clean up material and leaked and spilled fluids. 1. 2. 3. Disconnect hose (Figure 1, Item 4) from adapter (Figure 1, Item 3). Remove adapter (Figure 1, Item 3) from fuel shutoff valve (Figure 1, Item 2). Remove fuel shutoff valve (Figure 1, Item 2) from elbow (Figure 1, Item 1).
0763-2
TM 9-2320-272-23-4
0763
REMOVAL - Continued
1
3 2
M6153DAA
Figure 1. Fuel Burning Heater Fuel Shutoff Valve Removal. END OF TASK
0763-3
TM 9-2320-272-23-4
0763
INSTALLATION
NOTE
Clean all male pipe threads and wrap with antiseize tape before installation. 1. 2. 3. Install fuel shutoff valve (Figure 2, Item 2) on elbow (Figure 2, Item 1). Install adapter (Figure 2, Item 3) on fuel shutoff valve (Figure 2, Item 2). Connect hose (Figure 2, Item 4) to adapter (Figure 2, Item 3).
0763-4
TM 9-2320-272-23-4
0763
1
3 2
M6154DAA
Fuel Burning Heater Fuel Shutoff Valve Installation.
0763-5/6 blank
TM 9-2320-272-23-4
0764
FIELD MAINTENANCE PERSONNEL FUEL BURNING HEATER WIRING HARNESS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 283) Qty: 1 Lockwasher (Volume 5, WP 0827, Table 1, Item 422) Qty: 1 Tiedown Strap (Volume 5, WP 0827, Table 1, Item 375) Qty: 11 Personnel Required (2) Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Hood raised and secured. (TM 9-2320-272-10) Right and left splash shield removed. (TM 9-2320-272-10) Battery ground cables disconnected. (Volume 2, WP 0350)
0764-1
TM 9-2320-272-23-4
0764
REMOVAL 1. Remove locknut (Figure 1, Item 28), washer (Figure 1, Item 27), screw (Figure 1, Item 25), washer (Figure 1, Item 27), lockwasher (Figure 1, Item 26), and ground wire (Figure 1, Item 19) from mounting bracket (Figure 1, Item 16) and angle bracket (Figure 1, Item 14). Discard lockwasher and locknut.
NOTE
Note routing of wiring harness and leads for installation. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Disconnect heater harness connector (Figure 1, Item 22) from personnel heater (Figure 1, Item 15) and push harness connector (Figure 1, Item 22) into cab through grommet (Figure 1, Item 23). Remove grommet (Figure 1, Item 23) from firewall knockout (Figure 1, Item 17) and fuel pump lead (Figure 1, Item 10). Remove four tiedown straps (Figure 1, Item 11) from fuel pump lead (Figure 1, Item 10) and front harness (Figure 1, Item 13) on engine compartment firewall (Figure 1, Item 24). Discard tiedown straps. Disconnect leads (Figure 1, Items 10 and 21) from connector (Figure 1, Item 20) on cab (Figure 1, Item 18) and push lead (Figure 1, Item 10) through firewall (Figure 1, Item 24) into engine compartment. Remove three tiedown straps (Figure 1, Item 30) from fuel pump fuel lines (Figure 1, Item 31). Discard tiedown straps. Disconnect leads (Figure 1, Items 29 and 10) from fuel pump (Figure 1, Item 32). Disconnect heater harness (Figure 1, Item 6) and lead (Figure 1, Item 8) from heater control box (Figure 1, Item 5) and lead (Figure 1, Item 7). Disconnect lead (Figure 1, Item 9) from lead (Figure 1, Item 12) of wiring harness (Figure 1, Item 2). Remove four tiedown straps (Figure 1, Item 1) from heater harness (Figure 1, Item 6) on cab (Figure 1, Item 18). Discard tiedown straps. Disconnect wire (Figure 1, Item 4) from pin A of battery switch (Figure 1, Item 3) and remove wiring harness (Figure 1, Item 2) from cab (Figure 1, Item 18). Remove heater harness (Figure 1, Item 6) from cab (Figure 1, Item 18).
0764-2
TM 9-2320-272-23-4
0764
REMOVAL - Continued
5 3 2 1 22 23 24 7 21 8 20 4 6
9 10 19 11 24 13 14 17 16 15 12
18
25 19 26 16 27 14 32 10 31 29
30
27 28
M6155DAA
Figure 1. Personnel Fuel Burning Heater Wiring Harness Removal. END OF TASK
0764-3
TM 9-2320-272-23-4
0764
INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Install heater harness (Figure 2, Item 6) in cab (Figure 2, Item 18) with four tiedown straps (Figure 2, Item 1). Connect wire (Figure 2, Item 4) to pin A of battery switch (Figure 2, Item 3) and install wiring harness (Figure 2, Item 2) on cab (Figure 2, Item 18). Connect lead (Figure 2, Item 9) to lead (Figure 2, Item 12) of wiring harness (Figure 2, Item 2). Connect heater harness (Figure 2, Item 6) and lead (Figure 2, Item 8) to heater control box (Figure 2, Item 5) and lead (Figure 2, Item 7). Connect leads (Figure 2, Items 10 and 29) to fuel pump (Figure 2, Item 32). Install three tiedown straps (Figure 2, Item 30) on fuel pump fuel lines (Figure 2, Item 31). Push lead (Figure 2, Item 10) through firewall (Figure 2, Item 24) into cab (Figure 2, Item 18) and connect leads and (Figure 2, Item 21) to connector (Figure 2, Item 20) on cab. Install four tiedown straps (Figure 2, Item 11) on fuel pump lead (Figure 2, Item 10) and front harness (Figure 2, Item 13) on engine compartment firewall (Figure 2, Item 24). Install grommet (Figure 2, Item 23) on heater harness (Figure 2, Item 6) and firewall knockout (Figure 2, Item 17). Push harness connector (Figure 2, Item 22) into engine compartment through firewall knockout (Figure 2, Item 17) and connect heater harness connector to personnel heater (Figure 2, Item 15). Install washer (Figure 2, Item 27), lockwasher (Figure 2, Item 26), ground wire (Figure 2, Item 19), screw (Figure 2, Item 25), washer (Figure 2, Item 27), and locknut (Figure 2, Item 28) on mounting bracket (Figure 2, Item 16) and angle bracket (Figure 2, Item 14).
0764-4
TM 9-2320-272-23-4
0764
5 3 2 1 22 23 24 7 21 8 20 4 6
9 10 19 11 24 13 14 17 16 15 12
18
25 19 26 16 27 14 32 10 31 29
30
27 28
M6156DAA
Personnel Fuel Burning Heater Wiring Harness Installation.
0764-5
TM 9-2320-272-23-4
0764
FOLLOW-ON MAINTENANCE 1. 2. Connect battery ground cables. (Volume 2, WP 0350) Install right and left splash shield. (TM 9-2320-272-10)
0764-6
TM 9-2320-272-23-4
0765
FIELD MAINTENANCE PERSONNEL FUEL BURNING HEATER EXHAUST TUBE REPLACEMENT (M939/A1)
0765-1
TM 9-2320-272-23-4
0765
REMOVAL
WARNING
Do not handle hot exhaust tube with bare hands. Failure to comply may result in injury or death to personnel. 1. 2. 3. Remove cotter pin (Figure 1, Item 3) from exhaust elbow (Figure 1, Item 1) and fuel burning heater (Figure 1, Item 2). Discard cotter pin. Remove cotter pin (Figure 1, Item 4) from exhaust elbow (Figure 1, Item 1) and exhaust tube (Figure 1, Item 7). Discard cotter pin. Remove two locknuts (Figure 1, Item 6), screws (Figure 1, Item 9), clamps (Figure 1, Item 5), tube (Figure 1, Item 7), and exhaust elbow (Figure 1, Item 1) from fuel burning heater (Figure 1, Item 2) and splash panel (Figure 1, Item 8).
0765-2
TM 9-2320-272-23-4
0765
REMOVAL - Continued
1 2
5 4
9 7
M6157DAA
Figure 1. Fuel Burning Heater Exhaust Tube Removal. END OF TASK
0765-3
TM 9-2320-272-23-4
0765
INSTALLATION 1. 2. 3. Install exhaust tube (Figure 2, Item 7) and elbow (Figure 2, Item 1) on splash panel (Figure 2, Item 8) with two clamps (Figure 2, Item 5), screws (Figure 2, Item 9), and locknuts (Figure 2, Item 6). Install exhaust elbow (Figure 2, Item 1) on fuel burning heater (Figure 2, Item 2) with cotter pin (Figure 2, Item 3). Install exhaust elbow (Figure 2, Item 1) on exhaust tube (Figure 2, Item 7) with cotter pin (Figure 2, Item 4).
0765-4
TM 9-2320-272-23-4
0765
1 2
5 4
9 7
M6158DAA
Fuel Burning Heater Exhaust Tube Installation.
0765-5/6 blank
TM 9-2320-272-23-4
0766
FIELD MAINTENANCE PERSONNEL FUEL BURNING HEATER EXHAUST TUBE REPLACEMENT (M939A2)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Cotter Pin (Volume 5, WP 0827, Table 1, Item 350) Qty: 3 Locknut (Volume 5, WP 0827, Table 1, Item 61) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10) Equipment Condition (cont.) Hood raised and secured. (TM 9-2320-272-10)
0766-1
TM 9-2320-272-23-4
0766
REMOVAL
WARNING
Do not handle hot exhaust tube with bare hands. Failure to comply may result in injury or death to personnel. 1. 2. 3. Remove locknut (Figure 1, Item 10), washer (Figure 1, Item 9), screw (Figure 1, Item 8), and clamp (Figure 1, Item 7) from firewall (Figure 1, Item 1) and exhaust tube (Figure 1, Item 6). Discard locknut. Remove cotter pin (Figure 1, Item 5) and exhaust tube (Figure 1, Item 6) from elbow (Figure 1, Item 4). Discard cotter pin. Remove cotter pins (Figure 1, Items 3 and 11) and elbows (Figure 1, Items 4 and 12) from heater exhaust outlet (Figure 1, Item 2). Discard cotter pins.
0766-2
TM 9-2320-272-23-4
0766
REMOVAL - Continued
2 11 10 9 4 12 5 3
8 7 6
M6159DAA
Figure 1. Fuel Burning Heater Exhaust Tube Removal. END OF TASK
0766-3
TM 9-2320-272-23-4
0766
INSTALLATION 1. 2. 3. Install elbows (Figure 2, Items 4 and 12) on heater exhaust outlet (Figure 2, Item 2) with cotter pins (Figure 2, Items 3 and 11). Install exhaust tube (Figure 2, Item 6) on elbow (Figure 2, Item 4) with cotter pin (Figure 2, Item 5). Install clamp (Figure 2, Item 7) on exhaust tube (Figure 2, Item 6) and firewall (Figure 2, Item 1) with screw (Figure 2, Item 8), washer (Figure 2, Item 9), and locknut (Figure 2, Item 10).
2 11 10 9 4 12 5 3
8 7 6
M6160DAA
Fuel Burning Heater Exhaust Tube Installation.
0766-4
TM 9-2320-272-23-4
0767
FIELD MAINTENANCE PERSONNEL FUEL BURNING HEATER CIRCUIT BREAKER REPLACEMENT
0767-1
TM 9-2320-272-23-4
0767
REMOVAL 1. 2. Disconnect connectors (Figure 1, Item 3) and (Figure 1, Item 4) from heater circuit breaker (Figure 1, Item 1). Remove two screws (Figure 1, Item 2) and heater circuit breaker (Figure 1, Item 1) from left underside of dash (Figure 1, Item 5).
M6161DAA
Personnel Fuel Burning Heater Circuit Breaker Removal.
0767-2
TM 9-2320-272-23-4
0767
INSTALLATION 1. 2. Install heater circuit breaker (Figure 2, Item 1) on left underside of dash (Figure 2, Item 5) with two screws (Figure 2, Item 2). Connect connectors (Figure 2, Item 3) and (Figure 2, Item 4) to heater circuit breaker (Figure 2, Item 1).
M6162DAA
Figure 2. Personnel Fuel Burning Heater Circuit Breaker Installation. END OF TASK
0767-3
TM 9-2320-272-23-4
0767
0767-4
TM 9-2320-272-23-4
0768
FIELD MAINTENANCE DEEPWATER FORDING CONTROL CABLE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Locknut (Volume 5, WP 0827, Table 1, Item 282) Qty: 2 Materials/Parts (cont.) Locknut (Volume 5, WP 0827, Table 1, Item 312) Qty: 2 Lockwasher (Volume 5, WP 0827, Table 1, Item 411) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10) Hood raised and secured. (TM 9-2320-272-10)
0768-1
TM 9-2320-272-23-4
0768
REMOVAL 1. 2. 3. 4. Loosen screw (Figure 1, Item 1) and remove control cable (Figure 1, Item 10) from nut (Figure 1, Item 2) on pressurization valve (Figure 1, Item 3). Remove two locknuts (Figure 1, Item 11), screws (Figure 1, Item 4), clamp (Figure 1, Item 5), and control cable (Figure 1, Item 10) from fording cable bracket (Figure 1, Item 6). Discard locknuts. Remove nut (Figure 1, Item 16) and lockwasher (Figure 1, Item 17), and slide down control cable (Figure 1, Item 10). Pull hand control (Figure 1, Item 14) and control cable (Figure 1, Item 10) from instrument panel (Figure 1, Item 15) and grommet (Figure 1, Item 12) in firewall (Figure 1, Item 13), and remove nut (Figure 1, Item 16) and lockwasher (Figure 1, Item 17) from control cable. Discard lockwasher. Remove two locknuts (Figure 1, Item 9), screws (Figure 1, Item 7), and fording cable bracket (Figure 1, Item 6) from surge tank mounting bracket (Figure 1, Item 8). Discard locknuts.
5.
0768-2
TM 9-2320-272-23-4
0768
REMOVAL - Continued
13
1 2
12 11 3 4 5 10 17 10 9 8 7 14 16 6
15
M6163DAA
Deepwater Fording Control Removal.
0768-3
TM 9-2320-272-23-4
0768
INSTALLATION 1. 2. Install fording cable bracket (Figure 2, Item 6) on surge tank mounting bracket (Figure 2, Item 8) with two screws (Figure 2, Item 7) and locknuts (Figure 2, Item 9). Insert control cable (Figure 2, Item 10) and hand control (Figure 2, Item 14) through instrument panel (Figure 2, Item 15), lockwasher (Figure 2, Item 17), nut (Figure 2, Item 16), and grommet (Figure 2, Item 12) in firewall (Figure 2, Item 13), and tighten nut. Install control cable (Figure 2, Item 10) on fording cable bracket (Figure 2, Item 6) with clamp (Figure 2, Item 5), two screws (Figure 2, Item 4), and locknuts (Figure 2, Item 11). Install control cable (Figure 2, Item 10) in nut (Figure 2, Item 2) on pressurization valve (Figure 2, Item 3), and tighten screw (Figure 2, Item 1).
3. 4.
0768-4
TM 9-2320-272-23-4
0768
13
1 2
12 11 3 4 5 10 17 10 9 8 7 14 16 6
15
M6164DAA
Figure 2. Deepwater Fording Control Installation. END OF TASK END OF WORK PACKAGE
0768-5/6 blank
TM 9-2320-272-23-4
0769
FIELD MAINTENANCE DEEPWATER FORDING PRESSURIZATION VALVE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Tape, Antiseizing (Volume 5, WP 0825, Table 1, Item 65) Locknut (Volume 5, WP 0827, Table 1, Item 312) Qty: 2 Materials/Parts (cont.) Locknut (Volume 5, WP 0827, Table 1, Item 321) Qty: 1 Lockwasher (Volume 5, WP 0827, Table 1, Item 186) Qty: 1 Equipment Condition Parking brake set. (TM 9-2320-272-10) Hood raised and secured. (TM 9-2320-272-10) Air reservoirs drained. (TM 9-2320-272-10) Air pressure hose removed from valve (M939A2). (WP 0770)
0769-1
TM 9-2320-272-23-4
0769
REMOVAL (M939/A1)
WARNING
NOTE
Tag all hoses and lines for installation. All lines are removed the same way for M939/A1 and A2. 1. 2. 3. Remove two locknuts (Figure 1, Item 25), screws (Figure 1, Item 18), and clamp (Figure 1, Item 19) from fording cable bracket (Figure 1, Item 24). Discard locknuts. Loosen screw (Figure 1, Item 29) and remove control cable (Figure 1, Item 26) from nut (Figure 1, Item 28). Disconnect supply hose (Figure 1, Item 20) from pressurized valve adapter (Figure 1, Item 21).
NOTE
Perform Step (4) for vehicles equipped with positive crankcase ventilation system. 4. 5. 6. 7. Remove two clamps (Figure 1, Item 33), hose (Figure 1, Item 35), and crankcase vent tube (Figure 1, Item 32) from pressurization valve elbow (Figure 1, Item 34). Remove two clamps (Figure 1, Item 16), hose (Figure 1, Item 17), and crankcase breather tube (Figure 1, Item 15) from pressurization valve elbow (Figure 1, Item 27). Disconnect pressurization hose (Figure 1, Item 6) and vent hose (Figure 1, Item 5) from pressurization valve connectors (Figure 1, Item 7). Remove locknut (Figure 1, Item 8), screw (Figure 1, Item 12), clamp (Figure 1, Item 11), and power steering pump hose (Figure 1, Item 13) from bracket (Figure 1, Item 9) on radiator support bracket (Figure 1, Item 10). Discard locknut. Disconnect power steering pump hose (Figure 1, Item 13) from pressurization valve connector (Figure 1, Item 14). Remove two clamps (Figure 1, Item 1) and hose (Figure 1, Item 2) from crankcase breather (Figure 1, Item 3) and pressurization valve (Figure 1, Item 22). Remove screw (Figure 1, Item 30), lockwasher (Figure 1, Item 31), and pressurization valve (Figure 1, Item 22) with bracket (Figure 1, Item 23) from rocker lever cover (Figure 1, Item 4). Discard lockwasher.
8. 9. 10.
0769-2
TM 9-2320-272-23-4
0769
REMOVAL (M939/A1) - Continued
29 28 27 26 25 24 30 31
3 4 5 6 8 9 7 10 21 22 23 20 11
19
18
16 17 16 15 35 32 33
14 13 12
34
WITH POSITIVE CRANKCASE VENTILATION SYSTEM M939/A1
M6165DAA
Figure 1. Deepwater Fording Pressurization Valve Removal (M939/A1). END OF TASK
0769-3
TM 9-2320-272-23-4
0769
REMOVAL (M939/A2) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Remove two screws (Figure 2, Item 13), washers (Figure 2, Item 12), and pressurization valve (Figure 2, Item 3) from mounting bracket (Figure 2, Item 11) and bracket (Figure 2, Item 10). Remove screw (Figure 2, Item 5), washer (Figure 2, Item 6), spacer (Figure 2, Item 7), and arm (Figure 2, Item 4) from pressurization valve (Figure 2, Item 3). Remove connector (Figure 2, Item 1) from pressurization valve (Figure 2, Item 3). Remove tee (Figure 2, Item 2) from pressurization valve (Figure 2, Item 3). Remove adapter (Figure 2, Item 17) from tee (Figure 2, Item 18). Remove tee (Figure 2, Item 18) and connector (Figure 2, Item 19) from pressurization valve (Figure 2, Item 3). Remove regulator valve (Figure 2, Item 16) from elbow (Figure 2, Item 15). Remove elbow (Figure 2, Item 15) and connector (Figure 2, Item 14) from pressurization valve (Figure 2, Item 3). Remove elbow (Figure 2, Item 8) from pressurization valve (Figure 2, Item 3). Remove elbow (Figure 2, Item 9) from pressurization valve (Figure 2, Item 3).
0769-4
TM 9-2320-272-23-4
0769
4 5
18
19
3 6 7
17
10
16
12
15
13
11
14 M939A2
Figure 2. Deepwater Fording Pressurization Valve Removal (M939/A2). END OF TASK 0769-5
M6166DAA
TM 9-2320-272-23-4
0769
INSTALLATION (M939/A2)
NOTE
All male threads must be wrapped with antiseize tape before installation. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Install elbow (Figure 3, Item 9) on pressurization valve (Figure 3, Item 3). Install elbow (Figure 3, Item 8) on pressurization valve (Figure 3, Item 3). Install connector (Figure 3, Item 14) and elbow (Figure 3, Item 15) on pressurization valve (Figure 3, Item 3). Install regulator valve (Figure 3, Item 16) on elbow (Figure 3, Item 15). Install connector (Figure 3, Item 19) and tee (Figure 3, Item 18) on pressurization valve (Figure 3, Item 3). Install adapter (Figure 3, Item 17) on tee (Figure 3, Item 18). Install tee (Figure 3, Item 2) on pressurization valve (Figure 3, Item 3). Install connector (Figure 3, Item 1) on pressurization valve (Figure 3, Item 3). Install arm (Figure 3, Item 4) on pressurization valve (Figure 3, Item 3) with spacer (Figure 3, Item 7), washer (Figure 3, Item 6), and screw (Figure 3, Item 5). Install pressurization valve (Figure 3, Item 3) on mounting bracket (Figure 3, Item 11) and bracket (Figure 3, Item 10) with two washers (Figure 3, Item 12) and screws (Figure 3, Item 13).
0769-6
TM 9-2320-272-23-4
0769
INSTALLATION (M939/A2) - Continued
4 5
18
19
3 6 7
17
10
16
12
15
13
11
14 M939A2
Figure 3. Deepwater Fording Pressurization Valve Installation (M939/A2). END OF TASK 0769-7
M6167DAA
TM 9-2320-272-23-4
0769
NOTE
All male threads must be wrapped with antiseize tape before installation. 1. 2. 3. 4. 5. 6. Connect pressurization valve (Figure 4, Item 22) on crankcase breather (Figure 4, Item 3) with hose (Figure 4, Item 2) and two clamps (Figure 4, Item 1). Install pressurization valve bracket (Figure 4, Item 23) on rocker lever cover (Figure 4, Item 4) with lockwasher (Figure 4, Item 31) and screw (Figure 4, Item 30). Connect power steering pump hose (Figure 4, Item 13) to pressurization valve connector (Figure 4, Item 14). Install power steering pump hose (Figure 4, Item 13) on radiator support bracket (Figure 4, Item 10) and bracket (Figure 4, Item 9) with clamp (Figure 4, Item 11), screw (Figure 4, Item 12), and locknut (Figure 4, Item 8). Connect pressurization hose (Figure 4, Item 6) and vent hose (Figure 4, Item 5) to pressurization valve connectors (Figure 4, Item 7). Install crankcase breather tube (Figure 4, Item 15) on pressurization valve elbow (Figure 4, Item 27) with hose (Figure 4, Item 17) and two clamps (Figure 4, Item 16).
NOTE
Perform Step (7) for vehicles equipped with positive crankcase ventilation system. 7. 8. 9. 10. Install crankcase vent tube (Figure 4, Item 32) on pressurization valve elbow (Figure 4, Item 34) with hose (Figure 4, Item 35) and two clamps (Figure 4, Item 33). Connect supply hose (Figure 4, Item 20) to pressurized valve adapter (Figure 4, Item 21). Install control cable (Figure 4, Item 26) on nut (Figure 4, Item 28) and tighten screw (Figure 4, Item 29). Install control cable (Figure 4, Item 26) on fording cable bracket (Figure 4, Item 24) with clamp (Figure 4, Item 19), two screws (Figure 4, Item 18), and locknuts (Figure 4, Item 25).
0769-8
TM 9-2320-272-23-4
0769
2 1
3 29 28 27 26 25 24 30 31
5 6
8 9 7 2 10
21 20 19 18 16
22
23
11
14 13 17 16 15 35 34 32 33 12
WITH POSITIVE CRANKCASE VENTILATION SYSTEM M939/A1
M6168DAA
Figure 4. Deepwater Fording Pressurization Valve Installation (M939/A1). END OF TASK
0769-9
TM 9-2320-272-23-4
0769
FOLLOW-ON MAINTENANCE 1. 2. Connect air pressure hose to valve (M939A2). (WP 0770) Start engine and allow air pressure to build up to normal operating range. Check air for leaks. Road test vehicle. (TM 9-2320-272-10)
0769-10
TM 9-2320-272-23-4
0770
FIELD MAINTENANCE DEEPWATER FORDING AIR PRESSURE HOSE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Materials/Parts Tape, Antiseizing (Volume 5, WP 0825, Table 1, Item 65) Materials/Parts (cont.) Locknut (Volume 5, WP 0827, Table 1, Item 321) Qty: 2 Tiedown Strap (Volume 5, WP 0827, Table 1, Item 370) Qty: 5 Equipment Condition Parking brake set. (TM 9-2320-272-10) Hood raised and secured. (TM 9-2320-272-10) Air reservoirs drained. (TM 9-2320-272-10)
0770-1
TM 9-2320-272-23-4
0770
REMOVAL (M939/A1)
WARNING
Do not disconnect air lines or hoses before draining air reservoirs. Small parts under pressure may shoot out with high velocity. Failure to comply may result in injury or death to personnel. 1. Remove nut (Figure 1, Item 5), screw (Figure 1, Item 2), and clamp (Figure 1, Item 3) from supply hose (Figure 1, Item 4) and remove supply hose from pressurized valve (Figure 1, Item 6) and pressurized valve adapter (Figure 1, Item 1). Remove locknut (Figure 1, Item 26), screw (Figure 1, Item 24), clamp (Figure 1, Item 25), and power steering pump hose (Figure 1, Item 28) from bracket (Figure 1, Item 22). Discard locknut. Remove power steering pump hose (Figure 1, Item 28) from pressurized valve connector (Figure 1, Item 27) and adapter (Figure 1, Item 20). Remove five tiedown straps (Figure 1, Item 18) from pressure hose (Figure 1, Item 7) and vent hose (Figure 1, Item 8). Discard tiedown straps. Remove pressure hose (Figure 1, Item 7) and bushing (Figure 1, Item 17) from toe (Figure 1, Item 16) and pressurized valve connector (Figure 1, Item 31). Remove vent hose (Figure 1, Item 8) and bushing (Figure 1, Item 15) from toe (Figure 1, Item 14) and pressurized valve connector (Figure 1, Item 30). Remove air line (Figure 1, Item 9) from shutoff valve (Figure 1, Item 10) and alcohol evaporator (Figure 1, Item 13). Remove drain valve (Figure 1, Item 11) and elbow (Figure 1, Item 12) from alcohol evaporator (Figure 1, Item 13). Remove adapter (Figure 1, Item 20) from power steering pump (Figure 1, Item 21). Remove shutoff valve (Figure 1, Item 10) from air compressor (Figure 1, Item 19). Remove screw (Figure 1, Item 29) and bracket (Figure 1, Item 22) from radiator support bracket (Figure 1, Item 23).
2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
0770-2
TM 9-2320-272-23-4
0770
2 1
28 27 26 29 25 30 31 10 8 7 9 11 12 13
24
23
14 15 16 17
22 21 20
18 19
M6169DAA
Figure 1. Deepwater Fording Air Pressure Hose Removal (M939/A1). END OF TASK
0770-3
TM 9-2320-272-23-4
0770
REMOVAL (M939A2) 1. 2. 3. 4. 5. 6. 7. 8. Remove hose (Figure 2, Item 31) from elbows (Figure 2, Items 29 and 32) on air governor (Figure 2, Item 1) and pressurization valve (Figure 2, Item 21). Remove hose (Figure 2, Item 18) from elbow (Figure 2, Item 22) and connector (Figure 2, Item 19) on pneumatic controller (Figure 2, Item 23) and pressurization valve (Figure 2, Item 21). Remove hose (Figure 2, Item 17) from connectors (Figure 2, Item 16) and (Figure 2, Item 20) on air intake tube (Figure 2, Item 15) and pressurization valve (Figure 2, Item 21). Remove hose (Figure 2, Item 2) from connectors (Figure 2, Items 3 and 30) on tee (Figure 2, Item 4) and pressurization valve (Figure 2, Item 21). Remove hose (Figure 2, Item 5) from elbows (Figure 2, Items 6 and 9) on power steering reservoir (Figure 2, Item 13) and pressurization valve (Figure 2, Item 21). Remove hose (Figure 2, Item 14) from elbows (Figure 2, Items 12 and 28) on pressurization valve (Figure 2, Item 21). Remove clamp (Figure 2, Item 10) and hose (Figure 2, Item 8) from elbow (Figure 2, Item 11) on pressurization valve (Figure 2, Item 21). Remove two clamps (Figure 2, Item 26) and hose (Figure 2, Item 27) from elbows (Figure 2, Items 7 and 25) on rocker cover (Figure 2, Item 24) and pressurization valve (Figure 2, Item 21).
0770-4
TM 9-2320-272-23-4
0770
REMOVAL (M939A2) - Continued
1 2
32 31 3
26 27
29 28
30 6 5 7
4 8
26 25 21 20 13 19 14 24 23 18 17 16 15 22
M6170DAA
10 12 11
Figure 2. Deepwater Fording Air Pressure Hose Removal (M939A2). END OF TASK 0770-5
TM 9-2320-272-23-4
0770
INSTALLATION (M939A2)
NOTE
All male threads must be wrapped with antiseize tape before installation. 1. 2. 3. 4. 5. 6. 7. 8. Install hose (Figure 3, Item 27) on elbows (Figure 3, Items 7 and 25) on rocker cover (Figure 3, Item 24) and pressurization valve (Figure 3, Item 21) with two clamps (Figure 3, Item 26). Install hose (Figure 3, Item 8) on elbow (Figure 3, Item 11) on pressurization valve (Figure 3, Item 21) with clamp (Figure 3, Item 10). Install hose (Figure 3, Item 14) on elbows (Figure 3, Items 12 and 28) on pressurization valve (Figure 3, Item 21). Install hose (Figure 3, Item 5) on elbows (Figure 3, Items 6 and 9) on power steering reservoir (Figure 3, Item 13) and pressurization valve (Figure 3, Item 21). Install hose (Figure 3, Item 2) on connectors (Figure 3, Items 3 and 30) on tee (Figure 3, Item 4) and pressurization valve (Figure 3, Item 21). Install hose (Figure 3, Item 17) on connectors (Figure 3, Items 16 and 20) on air intake tube (Figure 3, Item 15) and pressurization valve (Figure 3, Item 21). Install hose (Figure 3, Item 18) on elbow (Figure 3, Item 22) and connector (Figure 3, Item 19) on pneumatic controller (Figure 3, Item 23) and pressurization valve (Figure 3, Item 21). Install hose (Figure 3, Item 31) on elbows (Figure 3, Items 29 and 32) on air governor (Figure 3, Item 1) and pressurization valve (Figure 3, Item 21).
0770-6
TM 9-2320-272-23-4
0770
INSTALLATION (M939A2) - Continued
1 2
32 31 3
26 27
29 28
30 6 5 7
4 8
26 25 21 20 13 19 14 24 23 18 17 16 15 22
M6171DAA
10 12 11
Figure 3. Deepwater Fording Air Pressure Hose Installation (M939A2). END OF TASK 0770-7
TM 9-2320-272-23-4
0770
NOTE
All male threads must be wrapped with antiseize tape before installation. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Install bracket (Figure 4, Item 22) on radiator support bracket (Figure 4, Item 23) with screw (Figure 4, Item 29). Install shutoff valve (Figure 4, Item 10) on air compressor (Figure 4, Item 19). Install elbow (Figure 4, Item 12) and drain valve (Figure 4, Item 11) on alcohol evaporator (Figure 4, Item 13). Install air line (Figure 4, Item 9) on shutoff valve (Figure 4, Item 10) and alcohol evaporator (Figure 4, Item 13). Install bushing (Figure 4, Item 16) on tee (Figure 4, Item 14). Install vent hose (Figure 4, Item 8) on bushing (Figure 4, Item 15) and pressurized valve connector (Figure 4, Item 30). Install bushing (Figure 4, Item 17) on tee (Figure 4, Item 16). Install pressure hose (Figure 4, Item 7) on bushing (Figure 4, Item 17) and pressurized valve connector (Figure 4, Item 31). Install five tiedown straps (Figure 4, Item 18) on pressure hose (Figure 4, Item 7) and vent hose (Figure 4, Item 8). Install adapter (Figure 4, Item 20) on power steering pump (Figure 4, Item 21). Install power steering pump hose (Figure 4, Item 28) on pressurized valve connector (Figure 4, Item 27) and adapter (Figure 4, Item 20). Install power steering pump hose (Figure 4, Item 28) on bracket (Figure 4, Item 22) with clamp (Figure 4, Item 25), screw (Figure 4, Item 24), and locknut (Figure 4, Item 26). Install supply hose (Figure 4, Item 4) on pressurized valve adapter (Figure 4, Item 1) and regulator valve (Figure 4, Item 6). Install clamp (Figure 4, Item 3) on supply hose (Figure 4, Item 4) with screw (Figure 4, Item 2) and nut (Figure 4, Item 5).
0770-8
TM 9-2320-272-23-4
0770
2 1
28 27 26 29 25 30 31 10 8 7 9 11 12 13
24
23
14 15 16 17
22 21 20
18 19
M6172DAA
Deepwater Fording Air Pressure Hose Installation (M939/A1).
0770-9
TM 9-2320-272-23-4
0770
FOLLOW-ON MAINTENANCE Start engine and allow air pressure to build up to normal operating range. Check for air leaks. Road test vehicle. (TM 9-2320-272-10) END OF TASK END OF WORK PACKAGE
0770-10
TM 9-2320-272-23-4
INDEX
Subject WP Sequence No.-Page No.
Miscellaneous
3 PHASE RECEPTACLE WIRING HARNESS REPLACEMENT..................................... 400 HZ CONVERTER HARNESS CONDUIT REPLACEMENT....................................... 400 HZ CONVERTER REPLACEMENT........................................................................... 400 HZ SUPPLY WIRING HARNESS REPLACEMENT.................................................. WP 0663-1 WP 0642-1 WP 0647-1 WP 0660-1
A
AIR CONDITIONER DRAIN TUBE REPLACEMENT....................................................... AIR CONDITIONER MANUAL STARTER SWITCHES REPLACEMENT........................ AIR CONDITIONER REPAIR............................................................................................ AUTOMATIC BRAKE (HOIST WINCH) SERVICING....................................................... WP 0633-1 WP 0645-1 WP 0652-1 WP 0708-1
B
BLACKOUT AND CLEARANCE LIGHTS WIRING HARNESS REPLACEMENT............ BLACKOUT AND EMERGENCY LIGHT FIXTURES REPLACEMENT............................ BLACKOUT BYPASS WIRING HARNESS REPAIR........................................................ BONNET ACCESS DOOR MAINTENANCE.................................................................... BONNET DOOR MAINTENANCE.................................................................................... BOOM ELEVATING CYLINDER REPLACEMENT........................................................... BOOM EXTENSION CYLINDER REPLACEMENT.......................................................... BOOM REPLACEMENT................................................................................................... BOOM ROLLER REPAIR................................................................................................. BRANCHED 400 HZ RECEPTACLE WIRING HARNESS REPLACEMENT................... WP 0659-1 WP 0644-1 WP 0657-1 WP 0650-1 WP 0651-1 WP 0693-1 WP 0695-1 WP 0686-1 WP 0688-1 WP 0661-1
C
CAB COWL VENT SCREEN AND DOOR REPLACEMENT............................................ CAB DOOR CATCH REPLACEMENT.............................................................................. CAB DOOR CHECK ROD REPLACEMENT.................................................................... CAB DOOR HINGE REPLACEMENT............................................................................... CAB GRAB HANDLE REPLACEMENT............................................................................ CAB HEAT AND DEFROST AIR DUCTING REPLACEMENT......................................... CAB HOOD STOP BRACKET REPLACEMENT.............................................................. CAB INSULATION REPLACEMENT................................................................................ CAB TOP SEAL AND RETAINER REPAIR...................................................................... CAB TURNBUTTONS AND LASHING HOOKS REPLACEMENT................................... CAB WINDSHIELD HINGE ASSEMBLY REPLACEMENT.............................................. CARGO BODY ASSEMBLY REPAIR............................................................................... CARGO BODY COVER BOWS REPLACEMENT............................................................ CARGO BODY FRAME RAIL SILL REPLACEMENT....................................................... CARGO LOWER WHEEL SPLASH GUARD REPLACEMENT........................................ CARGO STOWAGE BOX REPLACEMENT..................................................................... CARGO TAILGATE AND BUMPER REPLACEMENT...................................................... CARGO TROOP SEAT REPAIR...................................................................................... CARGO UPPER WHEEL SPLASH GUARD REPLACEMENT......................................... CIRCUIT BREAKER HARNESS AND CIRCUIT BREAKER REPLACEMENT................. COMPANION SEAT CUSHION, BACKREST CUSHION, AND FRAME REPLACEMENT............................................................................................................... CRANE BODY HOUSING ASSEMBLY COVER REPLACEMENT.................................. CRANE GONDOLA CONTROL VALVE REPAIR............................................................. WP 0572-1 WP 0557-1 WP 0555-1 WP 0556-1 WP 0570-1 WP 0744-1 WP 0563-1 WP 0580-1 WP 0733-1 WP 0732-1 WP 0579-1 WP 0588-1 WP 0731-1 WP 0593-1 WP 0734-1 WP 0587-1 WP 0590-1 WP 0589-1 WP 0596-1 WP 0636-1 WP 0581-1 WP 0665-1 WP 0698-1
Index-1
03/15/2011 Rel(1.8) root(aindx) wpno(B40009)
TM 9-2320-272-23-4
Subject
WP Sequence No.-Page No. WP 0707-1 WP 0690-1 WP 0691-1 WP 0689-1
CRANE HYDRAULIC FILTER AND HOUSING REPAIR.................................................. CRANE HYDRAULIC SWING MOTOR REPLACEMENT................................................ CRANE SWING GEARCASE REPLACEMENT............................................................... CRANE SWIVEL VALVE REPAIR....................................................................................
D
DEEPWATER FORDING AIR PRESSURE HOSE REPLACEMENT............................... DEEPWATER FORDING CONTROL CABLE REPLACEMENT...................................... DEEPWATER FORDING PRESSURIZATION VALVE REPLACEMENT......................... DEFROST AND HEAT CONTROLS REPLACEMENT..................................................... DIVERTER ASSEMBLY REPLACEMENT........................................................................ DRIVER'S SEAT CUSHION AND BACKREST CUSHION REPLACEMENT................... DRIVER'S SEAT, FRAME, AND BASE REPLACEMENT................................................ DUMP BODY HYDRAULIC HOSE REPLACEMENT....................................................... DUMP BODY REPAIR...................................................................................................... DUMP CAB PROTECTOR SHIELD REPAIR................................................................... DUMP CONTROL VALVE REPLACEMENT.................................................................... DUMP HOIST CYLINDER REPLACEMENT.................................................................... DUMP HYDRAULIC PUMP REPLACEMENT.................................................................. DUMP ROLLER ARM REPLACEMENT........................................................................... DUMP SAFETY BRACE REPLACEMENT....................................................................... DUMP SUBFRAME REPLACEMENT............................................................................... DUMP TAILGATE ASSEMBLY REPLACEMENT............................................................. DUMP TAILGATE CONTROL LINKAGE REPLACEMENT.............................................. DUMP VALVE CABLE AND SHIFT LEVER REPLACEMENT......................................... WP 0770-1 WP 0768-1 WP 0769-1 WP 0745-1 WP 0742-1 WP 0583-1 WP 0582-1 WP 0715-1 WP 0594-1 WP 0595-1 WP 0720-1 WP 0724-1 WP 0719-1 WP 0723-1 WP 0718-1 WP 0717-1 WP 0592-1 WP 0591-1 WP 0716-1
E
ELECTRIC HEATER (10 KW) WIRING HARNESS REPLACEMENT.............................. ELECTRICAL BOX REPLACEMENT............................................................................... ELECTRICAL JUNCTION BOX REPLACEMENT............................................................ ELECTRICAL LOAD CENTER BOX REPLACEMENT..................................................... ELECTRICAL LOAD CENTER CONDUIT REPLACEMENT............................................ EMERGENCY LAMP WIRING HARNESS REPLACEMENT........................................... ENGINE ACCESS COVER (IN-CAB) REPLACEMENT................................................... ENGINE COOLANT BATTERY BOX HEATER PAD REPLACEMENT............................ ENGINE COOLANT HEATER CONTROL BOX REPLACEMENT................................... ENGINE COOLANT HEATER HARNESS REPLACEMENT (M939/A1).......................... ENGINE COOLANT HEATER HARNESS REPLACEMENT (M939/A2).......................... ENGINE COOLANT HEATER HOSE REPLACEMENT................................................... ENGINE COOLANT HEATER PUMP REPLACEMENT................................................... ENGINE COOLANT HEATER REPLACEMENT.............................................................. ENGINE COOLANT OIL PAN SHROUD AND EXHAUST TUBE REPLACEMENT......... ENGINE HOOD REPLACEMENT..................................................................................... ENTRANCE RECEPTACLE 220V 3-PHASE WIRING HARNESS REPLACEMENT....... WP 0656-1 WP 0640-1 WP 0641-1 WP 0639-1 WP 0648-1 WP 0658-1 WP 0567-1 WP 0758-1 WP 0753-1 WP 0754-1 WP 0755-1 WP 0757-1 WP 0752-1 WP 0748-1 WP 0756-1 WP 0565-1 WP 0637-1
F
FENDER SPLASH SHIELD REPLACEMENT.................................................................. FLEXIBLE CONVERTER WIRING HARNESS REPLACEMENT..................................... FLUORESCENT LIGHT FIXTURES REPLACEMENT..................................................... FORWARD DECK PLATE REPLACEMENT.................................................................... FRESH AIR INLET DUCTING REPLACEMENT.............................................................. FRESH AIR VENT CONTROL CABLE ASSEMBLY REPLACEMENT............................. FRONT AND REAR WINCH CONTROL VALVE REPLACEMENT.................................. WP 0575-1 WP 0638-1 WP 0646-1 WP 0664-1 WP 0743-1 WP 0741-1 WP 0681-1
Index-2
TM 9-2320-272-23-4
Subject
WP Sequence No.-Page No. WP 0721-1 WP 0678-1 WP 0568-1 WP 0574-1 WP 0573-1 WP 0649-1 WP 0672-1 WP 0674-1 WP 0675-1 WP 0684-1 WP 0677-1 WP 0680-1 WP 0673-1 WP 0685-1 WP 0683-1 WP 0694-1 WP 0668-1 WP 0679-1 WP 0667-1
FRONT AND REAR WINCH CONTROL VALVE REPLACEMENT (M930/A1/A2)........... FRONT AND REAR WINCH LEVEL WIND REPAIR........................................................ FRONT CAB MOUNT REPLACEMENT........................................................................... FRONT FENDER EXTENSION REPLACEMENT............................................................ FRONT FENDERS REPLACEMENT................................................................................ FRONT WALL REGISTERS REPLACEMENT................................................................. FRONT WINCH AUTOMATIC BRAKE ADJUSTMENT.................................................... FRONT WINCH CABLE CHAIN AND HOOK REPLACEMENT....................................... FRONT WINCH CABLE CLEVIS REPLACEMENT.......................................................... FRONT WINCH CABLE REPLACEMENT........................................................................ FRONT WINCH CABLE TENSIONER REPAIR............................................................... FRONT WINCH CONTROL VALVE CABLE REPLACEMENT......................................... FRONT WINCH DRAG BRAKE ADJUSTMENT............................................................... FRONT WINCH HYDRAULIC HOSE AND TUBE REPLACEMENT................................ FRONT WINCH HYDRAULIC PUMP REPLACEMENT................................................... FRONT WINCH MOTOR REPLACEMENT...................................................................... FRONT WINCH REPLACEMENT..................................................................................... FRONT WINCH ROLLER ASSEMBLY REPAIR.............................................................. FUEL CAN BRACKET REPLACEMENT..........................................................................
G
GONDOLA REPAIR.......................................................................................................... WP 0699-1
H
HARDTOP KIT REPLACEMENT...................................................................................... HEATER FUEL PUMP WIRING HARNESS REPLACEMENT......................................... HEATER THERMOSTAT AND 10 KW HEATER THERMOSTAT REPLACEMENT........ HOIST LEVEL WIND REPLACEMENT............................................................................ HOIST WINCH CABLE REPLACEMENT......................................................................... HOIST WINCH REPLACEMENT...................................................................................... HOOD BUMPER REPLACEMENT................................................................................... HOOD GRAB HANDLE REPLACEMENT......................................................................... HOOD LATCH AND BRACKET REPLACEMENT............................................................ HOOD STOP CABLES REPLACEMENT......................................................................... HOOD SUPPORT BAR BRACKET, CROSSMEMBER, HINGES, AND TORSION BARS REPLACEMENT............................................................................................................... HYDRAULIC HOIST WINCH MOTOR AND LINES REPLACEMENT.............................. WP 0750-1 WP 0634-1 WP 0643-1 WP 0697-1 WP 0709-1 WP 0696-1 WP 0564-1 WP 0561-1 WP 0558-1 WP 0560-1 WP 0559-1 WP 0700-1
I
INNER BOOM REPLACEMENT....................................................................................... WP 0687-1
M
MAIN WIRING HARNESS REPLACEMENT.................................................................... MAP COMPARTMENT REPLACEMENT......................................................................... WP 0653-1 WP 0584-1
P
PERSONNEL FUEL BURNING HEATER AND MOUNTING BRACKET REPLACEMENT (M939/A1)......................................................................................................................... PERSONNEL FUEL BURNING HEATER AND MOUNTING BRACKETS REPLACEMENT (M939A2).............................................................................................. PERSONNEL FUEL BURNING HEATER CIRCUIT BREAKER REPLACEMENT........... PERSONNEL FUEL BURNING HEATER CONTROL BOX REPLACEMENT................. WP 0751-1 WP 0760-1 WP 0767-1 WP 0759-1
Index-3
TM 9-2320-272-23-4
Subject
WP Sequence No.-Page No.
PERSONNEL FUEL BURNING HEATER ELECTRIC FUEL PUMP REPLACEMENT (M939A2).......................................................................................................................... PERSONNEL FUEL BURNING HEATER EXHAUST TUBE REPLACEMENT (M939/ A1).................................................................................................................................... PERSONNEL FUEL BURNING HEATER EXHAUST TUBE REPLACEMENT (M939A2).......................................................................................................................... PERSONNEL FUEL BURNING HEATER FUEL PUMP REPLACEMENT (M939/A1)..... PERSONNEL FUEL BURNING HEATER FUEL SHUTOFF VALVE REPLACEMENT............................................................................................................... PERSONNEL FUEL BURNING HEATER WIRING HARNESS REPLACEMENT............ PERSONNEL HEATER HOSES REPLACEMENT........................................................... PERSONNEL HOT WATER HEATER REPLACEMENT.................................................. PRESSURE RELIEF VALVE ADJUSTMENT...................................................................
WP 0762-1 WP 0765-1 WP 0766-1 WP 0761-1 WP 0763-1 WP 0764-1 WP 0746-1 WP 0747-1 WP 0705-1
R
RADIATOR BAFFLES, SEALS, AND PLATES REPLACEMENT..................................... RADIATOR BRUSHGUARD REPLACEMENT................................................................. RADIATOR COVER KIT REPLACEMENT....................................................................... REAR CAB MOUNT REPLACEMENT.............................................................................. REAR DOOR REPAIR...................................................................................................... REAR WINCH ADJUSTMENT.......................................................................................... REAR WINCH CABLE REPLACEMENT.......................................................................... REAR WINCH CABLE TENSIONER REPAIR.................................................................. REAR WINCH HYDRAULIC MOTOR REPLACEMENT................................................... REAR WINCH REPLACEMENT....................................................................................... REAR WINCH ROLLER REPAIR..................................................................................... REARVIEW MIRROR AND BRACE REPLACEMENT..................................................... REFLECTORS REPLACEMENT...................................................................................... RIGHT AND LEFT SIDE BLACKOUT HARNESS REPAIR.............................................. WP 0562-1 WP 0576-1 WP 0749-1 WP 0569-1 WP 0601-1 WP 0669-1 WP 0710-1 WP 0722-1 WP 0682-1 WP 0670-1 WP 0676-1 WP 0738-1 WP 0740-1 WP 0635-1
S
SIDE LOCKING PIN RETAINING CLIP REPLACEMENT................................................ SNUBBER VALVE ASSEMBLY REPLACEMENT............................................................ WP 0597-1 WP 0706-1
T
TAILGATE PERSONNEL STEP REPLACEMENT........................................................... TELEPHONE POST WIRING HARNESS REPLACEMENT............................................. TOOLBOX AND STEPS REPLACEMENT....................................................................... TRACTOR WINCH HYDRAULIC OIL RESERVOIR REPLACEMENT (M932/A1/A2)...... TRANSFER CASE POWER TAKEOFF (PTO) CONTROL CABLE REPLACEMENT...... TRANSFER CASE POWER TAKEOFF (PTO) CROSS SHAFT (CONTROL LEVER) REPLACEMENT............................................................................................................... TRANSFER CASE POWER TAKEOFF (PTO) REPLACEMENT..................................... TRANSFER PTO-TO-HYDRAULIC PUMP PROPELLER SHAFT REPAIR..................... TRANSMISSION POWER TAKEOFF (PTO) CONTROL CABLE REPLACEMENT........ TRANSMISSION POWER TAKEOFF (PTO) CONTROL CABLE REPLACEMENT (M939A2).......................................................................................................................... TRANSMISSION POWER TAKEOFF (PTO) REPLACEMENT........................................ TRANSMISSION PTO-TO-HYDRAULIC PUMP PROPELLER SHAFT REPAIR............. TURNTABLE REPAIR...................................................................................................... WP 0598-1 WP 0662-1 WP 0586-1 WP 0702-1 WP 0726-1 WP 0727-1 WP 0725-1 WP 0714-1 WP 0729-1 WP 0730-1 WP 0728-1 WP 0713-1 WP 0692-1
Index-4
TM 9-2320-272-23-4
Subject
WP Sequence No.-Page No.
V
VAN AIR CONDITIONER WIRING HARNESS REPLACEMENT..................................... VAN BLACKOUT LIGHT SWITCH AND 110-VOLT RECEPTACLE REPLACEMENT.... VAN BONNET HANDLE AND CONTROL ROD REPLACEMENT................................... VAN DOOR CHECKS REPLACEMENT........................................................................... VAN DOOR HANDLE AND LOCK REPLACEMENT........................................................ VAN DOOR HINGE AND SEAL REPLACEMENT............................................................ VAN EMERGENCY/BLACKOUT LIGHT LAMP AND LENS REPLACEMENT................. VAN FLUORESCENT LIGHT TUBE REPLACEMENT..................................................... VAN HEATER AND EXHAUST REPLACEMENT............................................................. VAN HEATER FUEL PUMP REPLACEMENT (M934/A1/A2).......................................... VAN HEATER WIRING HARNESS REPLACEMENT...................................................... VAN HINGED END PANEL REPAIR................................................................................ VAN HINGED ROOF AND FLOOR COUNTERBALANCE CABLE REPLACEMENT...... VAN HINGED ROOF-OPERATED BLACKOUT CIRCUIT PLUNGERS REPLACEMENT............................................................................................................... VAN INSIDE TELEPHONE JACK POST REPLACEMENT.............................................. VAN LADDER LOCKING CLAMP REPLACEMENT......................................................... VAN LADDER RACK BUMPERS REPLACEMENT......................................................... VAN OUTSIDE TELEPHONE JACK POST REPLACEMENT.......................................... VAN PANEL SEALS REPLACEMENT............................................................................. VAN POWER CABLE REEL REPLACEMENT (M934A1/A2)........................................... VAN REAR DOOR AND SIDE DOOR WINDOW REPLACEMENT................................. VAN RETRACTABLE BEAM ASSEMBLY REPLACEMENT............................................ VAN RETRACTABLE WINDOW REGULATOR REPLACEMENT................................... VAN RETRACTABLE WINDOW REPLACEMENT........................................................... VAN SIDE AND REAR DOOR BLACKOUT LIGHT SWITCH REPLACEMENT............... VAN SIDE DOORS MAINTENANCE................................................................................ VAN SIDE PANEL EXTERIOR LOCK REPLACEMENT.................................................. VAN SIDE PANEL FRONT LOCK AND HINGED-TYPE ROOF LOCK REPLACEMENT............................................................................................................... VAN SIDE PANEL REAR LOCK REPLACEMENT........................................................... VAN SIDE PANEL ROOF SWIVEL HOOK REPLACEMENT........................................... VAN SIDE PANEL RUBBER BUMPERS REPLACEMENT.............................................. VAN SIDE PANEL-TO-ROOF TOGGLE CLAMP REPLACEMENT................................. VAN TOGGLE CLAMP ANCHOR POST REPLACEMENT.............................................. VAN WINDOW SCREEN REPLACEMENT...................................................................... VENT DOOR WEATHER SEAL REPLACEMENT............................................................ WP 0654-1 WP 0625-1 WP 0613-1 WP 0617-1 WP 0616-1 WP 0614-1 WP 0624-1 WP 0623-1 WP 0631-1 WP 0632-1 WP 0655-1 WP 0603-1 WP 0604-1 WP 0629-1 WP 0626-1 WP 0612-1 WP 0618-1 WP 0627-1 WP 0615-1 WP 0585-1 WP 0599-1 WP 0630-1 WP 0607-1 WP 0605-1 WP 0628-1 WP 0602-1 WP 0622-1 WP 0621-1 WP 0620-1 WP 0611-1 WP 0619-1 WP 0609-1 WP 0610-1 WP 0606-1 WP 0571-1
W
WASHER CONTROL VALVE REPLACEMENT............................................................... WINCH FRAME EXTENSION REPLACEMENT............................................................... WINCH HYDRAULIC OIL RESERVOIR FILTER REPLACEMENT.................................. WINCH HYDRAULIC OIL RESERVOIR REPLACEMENT............................................... WINDOW BLACKOUT PANEL REPLACEMENT............................................................. WINDOW BRUSH GUARD REPLACEMENT................................................................... WINDOW REGULATOR AND INSIDE DOOR HANDLE REPLACEMENT...................... WINDSHIELD AND OUTER FRAME ASSEMBLY REPLACEMENT............................... WINDSHIELD FRAME ASSEMBLY REPLACEMENT...................................................... WINDSHIELD STOP BRACKET AND LATCH REPLACEMENT..................................... WINDSHIELD WIPER BLADE, WIPER ARM, AND WIPER MOTOR REPLACEMENT............................................................................................................... WP 0739-1 WP 0671-1 WP 0704-1 WP 0701-1 WP 0554-1 WP 0600-1 WP 0608-1 WP 0577-1 WP 0578-1 WP 0566-1 WP 0736-1
Index-5
TM 9-2320-272-23-4
Subject
WP Sequence No.-Page No. WP 0735-1 WP 0737-1 WP 0666-1 WP 0711-1 WP 0712-1 WP 0703-1
WINDSHIELD WIPER CONTROL VALVE REPLACEMENT............................................ WINDSHIELD WIPER RESERVOIR, JET, CONTROL, AND WASHER HOSES REPLACEMENT............................................................................................................... WRECKER BODY REPLACEMENT................................................................................. WRECKER CRANE HYDRAULIC HOSE AND TUBE REPLACEMENT.......................... WRECKER CRANE HYDRAULIC PUMP REPLACEMENT............................................. WRECKER HYDRAULIC OIL RESERVOIR, BRACKETS AND STRAPS REPAIR.........
Index-6
RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS

For use of this form, see AR 25-30; the proponent agency is OAASA.
Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).
DATE Date you filled out this form.
TO (Forward to proponent of publication or form) (Include ZIP Code) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS
FROM (Activity and location) (Include ZIP Code)
Your mailing address
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TITLE
TM Number
ITEM PAGE PARAGRAPH LINE FIGURE TABLE NO.
Date of the TM
Title of the TM
RECOMMENDED CHANGES AND REASON (Exact wording of recommended change must be given)
0007-3
Figure 2, Item 9 should show a lockwasher. Currently shows a flat washer. Cleaning and inspection, Step 6, reference to governor support pin (14) is wrong reference. Reference should be change to (12).
0018-2
SAMPLE
TYPED NAME, GRADE OR TITLE
TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION
SIGNATURE
Your Name
DA FORM 2028, FEB 74
Your Phone Number
Your Signature
APD V4.00
REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.
TO (Forward direct to addressee listed in publication) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS
DATE Date you filled out this form
Your Address
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION NUMBER DATE TITLE
TM Number
PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER
Date of the TM
Title of the TM
RECOMMENDED ACTION
TOTAL NO. REFERENCE FIGURE ITEM OF MAJOR NO. NO. NO. ITEMS SUPPORTED
SAMPLE
PART III REMARKS (Any general remarks, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
Your Name
TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION
Your Phone Number
Your Signature
APD V4.00

For use of this form, see AR 25-30; the proponent agency is OAASA
DATE
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE PUBLICATION/FORM NUMBER DATE Truck, 5-Ton, 6X6, M939A1, And M939A2 Series Trucks 10 September 2012 TM 9-2320-272-23-4 (Diesel), Field Maintenance Manual PAGE PARAGRAPH LINE FIGURE TABLE NO. RECOMMENDED CHANGES AND REASON
SIGNATURE
APD V4.00
DATE
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE PUBLICATION/FORM NUMBER DATE Truck, 5-Ton, 6X6, M939A1, And M939A2 Series Trucks 10 September 2012 TM 9-2320-272-23-4 (Diesel), Field Maintenance Manual PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER REFERENCE FIGURE ITEM NO. NO. NO. TOTAL NO. OF MAJOR ITEMS SUPPORTED
RECOMMENDED ACTION
PART III REMARKS (Any general remarks, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
APD V4.00

DATE
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE PUBLICATION/FORM NUMBER DATE Truck, 5-Ton, 6X6, M939A1, And M939A2 Series Trucks 10 September 2012 TM 9-2320-272-23-4 (Diesel), Field Maintenance Manual ITEM PAGE PARAGRAPH LINE FIGURE TABLE NO. RECOMMENDED CHANGES AND REASON
SIGNATURE
APD V4.00
DATE
RECOMMENDED ACTION
PART III REMARKS (Any general remark, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
APD V4.00

DATE
SIGNATURE
APD V4.00
DATE
RECOMMENDED ACTION
PART III REMARKS (Any general remarks, recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
APD V4.00

DATE
SIGNATURE
APD V4.00
DATE
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE PUBLICATION/FORM NUMBER DATE Truck, 5-Ton, 6X6, M939A1, And M939A2 Series Trucks 10 September 2012 TM 9-2320-272-23-4 (Diesel), Field Maintenance Manual PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER REFERENCE FIGURE ITEM NO. NO. NO. TOTAL NO. OF MAJOR ITEMS SUPPORTED RECOMMENDED ACTION
PART III REMARKS (Any general remarks, recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
APD V4.00
By Order of the Secretary of the Army: RAYMOND T. ODIERNO General, United States Army Chief of Staff
Official:
JOYCE E. MORROW Administrative Assistant to the Secretary of the Army

1220212
By Order of the Secretary of the Air Force: DONALD J. HOFFMAN General, United States Air Force Commander, AFMC NORTON A. SCHWARTZ General, United States Air Force Chief of Staff
Distribution: To be distributed in accordance with the initial distribution number (IDN) 386968 requirements for TM 9-2320-272-23-4.
THE METRIC SYSTEM AND EQUIVALENTS

LINEAR MEASURE 1 Centimeter=10 Millimeters=0.01 Meters=0.3937 Inches 1 Meter=100 Centimeters=1000 Millimeters=39.37 Inches 1 Kilometer=1000 Meters=0.621 Miles WEIGHTS 1 Gram=0.001 Kilograms=1000 Milligrams=0.035 Ounces 1 Kilogram=1000 Grams=2.2 Lb 1 Metric Ton=1000 Kilograms=1 Megagram=1.1 Short Tons LIQUID MEASURE 1 Milliliter=0.001 Liters=0.0338 Fluid Ounces 1 Liter=1000 Milliliters=33.82 Fluid Ounces SQUARE MEASURE 1 Sq Centimeter=100 Sq Millimeters=0.155 Sq Inches 1 Sq Meter=10,000 Sq Centimeters=10.76 Sq Feet 1 Sq Kilometer=1,000,000 Sq Meters=0.386 Sq Miles CUBIC MEASURE 1 Cu Centimeter=1000 Cu Millimeters=0.06 Cu Inches 1 Cu Meter=1,000,000 Cu Centimeters=35.31 Cu Feet TEMPERATURE 5/9 (F 32) = C 212Fahrenheit is equivalent to 100Celsius 90Fahrenheit is equivalent to 32.2Celsius 32Fahrenheit is equivalent to 0Celsius 9/5 (C + 32) = F
APPROXIMATE CONVERSION FACTORS

15
TO CHANGE Inches . . . . . . . . . . . Feet . . . . . . . . . . . . . Yards . . . . . . . . . . . . Miles . . . . . . . . . . . . Square Inches . . . . Square Feet . . . . . . . Square Yards . . . . . . Square Miles . . . . . . Acres . . . . . . . . . . . . Cubic Feet . . . . . . . . Cubic Yards . . . . . . . Fluid Ounces . . . . . . Pints. . . . . . . . . . . . . Quarts . . . . . . . . . . . Gallons. . . . . . . . . . . Ounces . . . . . . . . . . Pounds . . . . . . . . . . . Short Tons . . . . . . . . Pound-Feet . . . . . . . Pounds/Sq Inch . . . . Miles per Gallon . . . . Miles per Hour . . . . . TO CHANGE Centimeters . . . . . . . Meters . . . . . . . . . . . Meters . . . . . . . . . . . Kilometers . . . . . . . . Sq Centimeters . . . . Square Meters . . . . . Square Meters . . . . . Square Kilometers . . Sq Hectometers . . . . Cubic Meters . . . . . . Cubic Meters . . . . . . Milliliters . . . . . . . . . . Liters . . . . . . . . . . . . Liters . . . . . . . . . . . . Liters . . . . . . . . . . . . Grams . . . . . . . . . . . Kilograms . . . . . . . . . Metric Tons . . . . . . . Newton-Meters. . . . . Kilopascals. . . . . . . . Km per Liter . . . . . . . Km per Hour . . . . . .
TO
MULTIPLY BY 2.540 0.305 0.914 1.609 6.451 0.093 0.836 2.590 0.405 0.028 0.765 29.573 0.473 0.946 3.785 28.349 0.454 0.907 1.356 6.895 0.425 1.609
Inches . . . . . . . . . . . . . . . . . . . . . Feet . . . . . . . . . . . . . . . . . . . . . . . Yards . . . . . . . . . . . . . . . . . . . . . . Miles . . . . . . . . . . . . . . . . . . . . . . Square Inches . . . . . . . . . . . . . . . Square Feet. . . . . . . . . . . . . . . . . Square Yards . . . . . . . . . . . . . . . . Square Miles . . . . . . . . . . . . . . . . Acres . . . . . . . . . . . . . . . . . . . . . . Cubic Feet . . . . . . . . . . . . . . . . . . Cubic Yards . . . . . . . . . . . . . . . . . Fluid Ounces . . . . . . . . . . . . . . . . Pints . . . . . . . . . . . . . . . . . . . . . . Quarts . . . . . . . . . . . . . . . . . . . . . Gallons . . . . . . . . . . . . . . . . . . . . Ounces . . . . . . . . . . . . . . . . . . . . Pounds . . . . . . . . . . . . . . . . . . . . Short Tons . . . . . . . . . . . . . . . . . . Pound-Feet . . . . . . . . . . . . . . . . . Pounds per Sq Inch . . . . . . . . . . . Miles per Gallon . . . . . . . . . . . . . Miles per Hour . . . . . . . . . . . . . . .
0.394 3.280 1.094 0.621 0.155 10.764 1.196 0.386 2.471 35.315 1.308 0.034 2.113 1.057 0.264 0.035 2.205 1.102 0.738 0.145 2.354 0.621
TO
MULTIPLY BY
1 CM. 2
INCHES
Centimeters . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . . . . . Kilometers . . . . . . . . . . . . . . . . . . Square Centimeters . . . . . . . . . . Square Meters . . . . . . . . . . . . . . . Square Meters . . . . . . . . . . . . . . . Square Kilometers. . . . . . . . . . . . Square Hectometers . . . . . . . . . . Cubic Meters . . . . . . . . . . . . . . . . Cubic Meters . . . . . . . . . . . . . . . . Milliliters. . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . Grams . . . . . . . . . . . . . . . . . . . . . Kilograms. . . . . . . . . . . . . . . . . . . Metric Tons . . . . . . . . . . . . . . . . . Newton-Meters . . . . . . . . . . . . . . Kilopascals . . . . . . . . . . . . . . . . . Kilometers per Liter . . . . . . . . . . . Kilometers per Hour . . . . . . . . . .
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14
11
12
10
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ARMY *TM 9-2320-272-23-4 AIR FORCE *TO 36A12-1C-1155-2-4

TECHNICAL MANUAL FIELD MAINTENANCE MANUAL FOR

TRUCK, DUMP: 5-TON, 6X6

TRUCK, VAN, EXPANSIBLE: 5-TON, 6X6

TRUCK, MEDIUM WRECKER: 5-TON, 6X6

TRUCK, CARGO: 5-TON, 6X6 XLWB

TRUCK, TRACTOR: 5-TON, 6X6

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

03/15/2011 Rel(1.8) root(warnsum) wpno(F00008)

WARNING SUMMARY - Continued

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WARNING SUMMARY - Continued

GENERAL SAFETY WARNINGS DESCRIPTION

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WARNING SUMMARY - Continued

EXPLANATION OF HAZARDOUS MATERIALS ICONS

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WARNING SUMMARY - Continued

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WARNING SUMMARY - Continued

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WARNING SUMMARY - Continued

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WARNING SUMMARY - Continued

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WARNING SUMMARY - Continued

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LIST OF EFFECTIVE PAGES/WORK PACKAGES

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*TM 9-2320-272-23-4 *TO 36A12-1C-1155-2-4

TRUCK, DUMP: 5-TON, 6X6

TRUCK, VAN, EXPANSIBLE: 5-TON, 6X6

TRUCK, MEDIUM WRECKER: 5-TON, 6X6

TRUCK, CARGO: 5-TON, 6X6 XLWB

TRUCK, TRACTOR: 5-TON, 6X6

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TABLE OF CONTENTS - Continued

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RADIATOR BRUSHGUARD REPLACEMENT............................................................................................ WP 0576 Figure 1. Radiator Brushguard Removal............................................................................................. 0576-3

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DRIVER'S SEAT, FRAME, AND BASE REPLACEMENT........................................................................... WP 0582

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ARMY TM 9-2320-272-23-4 AIR FORCE TO 36A12-1C-1155-2-4

TM 9-2320-272-23-4 TO 36A12-1C-1155-2-4